2006 txt will not move

[msubdawg]

My TXT was working fine with new batteries for a few months. About a week ago it stopped working. I followed the troubleshooting procedure posted on this web site and leads me to a bad resistor on the solenoid. I am reading 37.7 V on battery side of solenoid and 22.1 on the controller side. The resistor is very warm. When I remove the resistor it read 250 ohms. When I remove the resistor from the controller side of the solenoid and leave it attached to the battery side I read 37.7 one battery side and 37.6 on the unattached end. Is the resistor bad?

[JohnnieB]

Originally Posted by msubdawg

My TXT was working fine with new batteries for a few months. About a week ago it stopped working. I followed the troubleshooting procedure posted on this web site and leads me to a bad resistor on the solenoid. I am reading 37.7 V on battery side of solenoid and 22.1 on the controller side. The resistor is very warm. When I remove the resistor it read 250 ohms. When I remove the resistor from the controller side of the solenoid and leave it attached to the battery side I read 37.7 one battery side and 37.6 on the unattached end. Is the resistor bad?

Welcome to BGW!

Good or bad, the resistor is not the problem. Cart will run without it installed.
All it does is keep the solenoid contact from arcing as much when they close, prolonging their useful life.

The 15.6V drop (37.7 - 22.1 = 15.6) tells me you have a bad controller, or the solenoid contacts are not closing when the pedal is pushed.

Does the solenoid click when the pedal is pushed?

Need to know what type drive system (Series or PDS) to troubleshoot further.

[msubdawg]

Thanks for the response. It is a series TXT. The solenoid clicking and I get 37.7 volts to the controller and out of the controller to the motor but the motor will not run.

[msubdawg]

Also, getting 22 volts out of the controller and to the motor on all 4 posts. The key switch can be on or off and still getting 22 volts on M post of controller and all 4 motor posts.

[JohnnieB]

Jack rear tires off ground so cart won't take off unexpectedly.

Remove the resistor to make troubleshooting easier.
Connect your negative DVM test lead to B- terminal on controller.
Connect the positive lead to the M- terminal on the controller.

Key = On, F/R in either F or R and pedal only pushed until solenoid clicks.

You should read FULL battery pack voltage (37.7V ?)
If zero volts, there is an open in the high current circuit. Highlighted on attached schematic.

If less than FULL pack voltage, you may have a bad controller.

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BTW: The battery pack needs to be charged. It only 86% charged.

[msubdawg]

Thanks for the procedure. Here are my results.
Key on, forward switch in F, push pedal until solenoid clicks, and I get 37.7 volts across B- and M-.

What should my voltage be when fully charged?

[JohnnieB]

Originally Posted by msubdawg

Thanks for the procedure. Here are my results.
Key on, forward switch in F, push pedal until solenoid clicks, and I get 37.7 volts across B- and M-.

What should my voltage be when fully charged?

If 37.7V is the same as the voltage you measure between the main negative terminal and main positive terminal on the battery pack, that reading is what it should be.

Next step is to slowly press the pedal to the floor. The voltage between B- and M- should smoothly decrease to near zero.

If it doesn't, the throttle input to the controller is bad, or the controller is bad.

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When measered about 12 hours after the charger shuts off, a fully charged 36V pack should read 38.2V.

Here is a SoC vs Voltage chart.

[msubdawg]

When I push the pedal to the floor it the voltage remains at 37.7 volts. Is there a way to determine which one it is, the throttle input or the controller?

[JohnnieB]

Originally Posted by msubdawg

When I push the pedal to the floor it the voltage remains at 37.7 volts. Is there a way to determine which one it is, the throttle input or the controller?

To check ITS, connect DVM between B- terminal on controller and Pin-2 (Black wire) in connector on top of controller.

Voltage should be between 9.0V and 11.5V.

Then connect DVM between B- and Pin-1 (White wire).
When solenoid first clicks, the voltage should be between 0.4V and 0.6V.
Press pedal to floor and the voltage should be between 1.5V and 1.7V.

If you are getting the correct ITS voltage readings, the controller is probably bad.

[msubdawg]

Thanks. I will try this tonight when I get home.