2004 TXT won't go

[scottyb]

For clarification the 'not quite red' light is an orange signaling full throttle input. You should not get this signal until the second half of the gas peddle throw or stroke.
'Cart bucking' indicates solenoid dropping out and picking back up rapidly. This happens when the voltage supply is below what's required.

[olewis76]

JohnnieB: 1&2. The cart is a 36V, with 38.3V across the pack roughly 12 hours after the charger shuts off.
3. Neither have gotten wet that recently.
4. The cart has 23-10.5-12 tires on it.

[olewis76]

The solenoid that I bought was not sufficient according to the Alltrax websit and post, so I purchased the correct solenoid and installed. Same problem exists.
I have tried to follow the troubleshooting guide from the EZGO technicians manual, but some of the directions don't match up since I don't have a stock controller. Based on what I have been able to follow, I think that the motor and controller are good, battery pack is good. Is there any chance that it could be the F&R switch? How would I check this?

[JohnnieB]

Here is a schematic of a DCX controller in a PDS cart and you can download a clearer version in a .pdf format from the AllTrax site.

I'm very good at reading schematics, but I have a lot of trouble tracing current paths from the stock cart wiring to the DCX controller through the adapter, so let's start at the controller pins and find out what is missing, then backtrack from there.

With Run/Tow switch in Run, Keyswitch ON and F/R switch in Forward, you should have B+ (Positive battery pack voltage) on controller pins 5, 6, 9 & 10

With Run/Tow switch in Run, Keyswitch ON and F/R switch in Reverse, you should have B+ (Positive battery pack voltage) on controller pins 4, 5, 6, 9 & 10

In either of the two conditions above, Pin-7 will have B+ with pedal up and Zero volts with pedal pushed.

Lets us know what is missing and we will proceed from there.

[olewis76]

Thanks for all the help, but the wife put a time limit on me and I couldn't get it done. It's off to the shop for repairs. Will let you know what happens!

[olewis76]

Guy at the shop says windings are grounded and brushes are shot. Motor is bad...