Possible throttle issue

[Mryno]

Hey guys! I purchased a 2013 EzGo TXT 48v PDS and have been refurbishing it )I actually bought 3 but I'm only keeping 1). It had a bad battery, so I swapped one from one of the other carts and voltage reads normal and all connections have been tightened. After replacing the battery, I went to move the cart back into the garage and the accelerator pedal was binding and was stuck. I pushed harder and it returned to full range of motion. Now, when I push the pedal, I can hear the solenoid engage and can get the cart to crawl forward/backward but if I push the throttle any further than where the solenoid engages, it cuts power and the solenoid kicks off after a few seconds. I was thinking maybe it was the throttle sensor, but wasn't sure. The cart's throttle seemed to work just fine this morning when I moved it out of the garage. It's very odd as all I did was take a battery out and out another in. I put it in tow mode before working on it. I've tried cycling it in/out of tow mode as well as charging the batteries. The batteries are reading normal before I tried to charge them.

Any ideas? I'm very new to carts so the troubleshooting process is a little foggy for most things. I've been searching for a similar issue and will probably start swapping parts from the other carts after inspecting the throttle sensor area to see if anything is obviously out of place. Any help is greatly appreciated!

[Mryno]

Went back out to try it and it won't go at all. I can hear the click from the microswitch (I assume that's what it is) but the solenoid never kicks on. Maybe it's the microswitch...?

[yurtle]

Hook up a volt meter to the battery pack and tell us what you read at rest, then when you are trying to go. There's no guarantee the replacement battery is good. Sometimes they read OK with no load, but drop down too much under load.

[Mryno]

At rest, I'm reading 52.5 (and dropping because it was on the charger a bit ago) and there is no drop when the throttle is pressed. I did that before when I could get it to crawl around and I want to say it was still above 50 volts but I didn't think to write it down at the time because I knew the new (to this cart) battery was probably lower than the others.

[yurtle]

No need to repeat for an exact number. That isn't you problem.

EDIT:
On the label on the controller cover there should be instructions on how to place you controller in "maintenance" (or something like that) mode. Not run/tow, but a troubleshooting mode. I don't know anything abour PDS carts, but as I understand it, while driving around the controller will give you beep codes, which should be on the label as well.

[Mryno]

I popped open the throttle box. Found the issue. Basically, it looks like maybe the plastic box has deformed or the metal plunger wasn't aligned. That resistance I felt must have been the plunger against the ITS. It busted the ITS (copper windings visible) and broke the ITS off its plastic terminals. I need a new ITS and the box/housing. This doesn't look fun to change...

[yurtle]

http://products.jacobsen.com/img/manuals/28646.pdf

Should provide instructions for replacement AND adjustment. There may be a newer manual in the Stickies. The procedure should be the same, but I seem to recall the drill bit being different on some models. ScottyB mentioned this a while back, and may chime in.

[Mryno]

Thanks a ton! I got the assembly out pretty easily. 4 bolts and 2 rivets and a connector. Ordered a remanufactured replacement from buggies unlimited. I really appreciate the help!!

[yurtle]

Originally Posted by Mryno

Thanks a ton! I got the assembly out pretty easily. 4 bolts and 2 rivets and a connector. Ordered a remanufactured replacement from buggies unlimited. I really appreciate the help!!

Buggies or Carts?