99 EZGO TXT DCS Shutters and Will Not Move

R

rctjcmo

New Member
Hi. I am new to this forum and I hope I can get some help. I have a 1999 EZGO TXT DCS with a 10 pin controller. After setting for a while, it would not move. I have a shop manual and went through the tests and started replacing parts according to the manual. I replaced the batteries, solenoid, resistor/diode, forward and reverse micro switches, controller and throttle sensor. I get all of the proper readings at the solenoid and on the controller pins according to the manual. When the cart is up on jack stands, the tires will turn but the acceleration is sluggish and not fast at all. When the cart wheels are on the ground, the cart just shudders. I don't know what to do next. Please help. Thank you.
 
I have not. Since the motor would spin while the cart was up on blocks I assumed it was okay. I will look in the service manual how to test it and see what happens. Thank you.
 
I took out the motor and cleaned it. The commutator has numerous groves worn into it about a sixteenth of an inch deep and of course the brushes have the same wear pattern. I put the motor back in with no improvement. The motor will run while the cart is up on blocks, but acceleration is very sluggish.
I have not seen anywhere what the voltage or amperage measurements should be at the motor minus terminal on the controller. The amperage starts at 0 and goes up to 16 amps at full throttle. The voltage starts at 4, goes up to 10 and goes back down to 4 at full throttle. The battery pack voltage is 37.89 after charging. Any more ideas would be greatly appreciated.
 
rctjcmo said:
I took out the motor and cleaned it. The commutator has numerous groves worn into it about a sixteenth of an inch deep and of course the brushes have the same wear pattern. I put the motor back in with no improvement. The motor will run while the cart is up on blocks, but acceleration is very sluggish.
I have not seen anywhere what the voltage or amperage measurements should be at the motor minus terminal on the controller. The amperage starts at 0 and goes up to 16 amps at full throttle. The voltage starts at 4, goes up to 10 and goes back down to 4 at full throttle. The battery pack voltage is 37.89 after charging. Any more ideas would be greatly appreciated.
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grooves like that are not surprising at that age

how are you measuring the DC amperage ?

37.89 is about 90%
is the water over the plates in each cell of each battery?
how old are the batteries? , around 5 years is the average life
you should have them load tested

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I took the readings with a Kaiweets clamp meter. The batteries are new. Just to be safe, I charged them before doing these tests.
 
rctjcmo said:
I took the readings with a Kaiweets clamp meter. The batteries are new. Just to be safe, I charged them before doing these tests.
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if the cart was on jack stands it is not going to pull large amps
what you need to do now is voltage testing
1) for the throttle input to the controller , make sure you are getting full signal into the controller and not just the connector
2) on the controller ,,, measure from B- to M- at full throttle, you should see pack voltage
 
When I pulled up on the connector to get to the pins, there was a snap sound and a small arc. I suspect that the connector is not making contact. I ordered a new one and will report back when I get it installed.
 
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