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Old 09-28-2015, 03:59 PM   #1
Sinecure
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Default Cart intermittently won't go

A buddy of mine has a 2001 EZGO TXT (series) golf cart that he purchased about a year ago. New batteries installed the day he bought the cart. He has always had a problem with the cart dying on him with a full charge after not much use, usually about 20 minutes of run time. The solenoid will click, but no go. The lights will dim to almost nothing when the pedal is pressed. However, let it sit (not charging) for 10-20 minutes and it will run perfectly.

We suspected the controller, so I loaned him a Alltrax AXE-4845 to test this theory. With the new controller the cart has more torque and a little more top end, but does the same thing after about 20 minutes of run time. What do you guys think could be causing this? Batteries don't recharge themselves that quickly without being plugged in. The motor gets a hot, as in it would be uncomfortable to hold your hand on it for too long, but it isn't much hotter than the motor on my cart. Any suggestions on what to try next?
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Old 09-28-2015, 04:25 PM   #2
scottyb
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Default Re: Cart intermittently won't go

Install a digital voltmeter directly to the battery pack and see whats happening to the pack when the cart won't go.... how far is the pack voltage dropping?
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Old 09-28-2015, 04:38 PM   #3
Sinecure
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Default Re: Cart intermittently won't go

Thanks, I'll tell him to do that and will report back here. Have you ever seen or heard of the battery pack voltage dropping like that, then coming back to normal levels after letting it sit (not charging)?
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Old 09-28-2015, 06:34 PM   #4
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Default Re: Cart intermittently won't go

When you say "After letting it sit"...."then it runs perfectly" you don't say for how long it "runs perfectly". So.....how long?
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Old 09-28-2015, 07:22 PM   #5
Sinecure
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Default Re: Cart intermittently won't go

After sitting, it will run for the same amount of time, another 20 minutes or so.
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Old 09-28-2015, 07:34 PM   #6
scottyb
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Default Re: Cart intermittently won't go

They do recover but??? lets get some voltage readings
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Old 09-28-2015, 08:51 PM   #7
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Default

Also, while getting those volt readings for Scotty, check all the connections. I had one that was doing the same thing. checked everything I could think of and it turned out to be one of the battery cables were almost corroded into under the heat shrink at the lug and it couldn't be seen. So twist and pull them to make sure they are all good.
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Old 09-29-2015, 07:47 AM   #8
radioman
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Default Re: Cart intermittently won't go

A poor connection in the high current wiring will usually get hot. Check connections when cart stalls.
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Old 09-29-2015, 08:26 AM   #9
Sinecure
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Default Re: Cart intermittently won't go

We have checked all connections from the batteries, to the F-N-R switch, to the solenoid, controller, and motor several times both before and after riding. All are clean and tight.

Thanks for all the suggestions, please keep them coming. Eventually we'll stumble upon the problem.
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Old 09-29-2015, 09:13 AM   #10
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Also check the 4 pin Molex connector that connects the ITS and the controller. It has been known to cause intermittent problems.
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