Hot Rod, any other EzGo Experts---

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06z400rider

New Member
I had a customer bring a 2004 EzGo TXT in today after taking it to another cart shop and being told the motor and controller were bad. This cart is nice. I pulled the motor and tested it- good. I am following the steps from the troubleshooting guide and get to step 17- checking voltage from B- to red wire in pedal box. I open the lid, and the screws were already loose. The black and white wire are hooked up to the ITS, but the red and green wires are just loose in there, and there's nothing to hook them to, that I can see. Shouldn't there be a microswitch or something? Also, the solenoid had gotten HOT at the diode. The diode was gone and there was a black weld spot from arching. I was getting pack voltage on either side of the solenoid, so I changed it with a solenoid off of a 2006 PDS. It looked identical, but I then had 38 volts on the battery side and 27 volts on the controller side, and the troubleshooting manual says .5-2.5 volts drop is proper...Is this ok, or do I need another solenoid? I just pulled this one off of a working PDS a week ago. Thanks for the help!
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Yes there should be a micro switch in the pedal box.
If the diode on the solenoid is getting hot and you get strange voltage readings at the solenoid it usually a bad controller.
 
Thanks, HRC! I stayed with it, I saw two holes in the pedal box where a microswitch must go. Those idiots robbed it out of the box, probably to make it harder for someone else to troubleshoot. Anyhow, I took a male plug and butt spliced it to the red wire, then connected the green and red, as though the pedal was pushed down. The solenoid started clicking as it should. Still no movement. I continued the troubleshooting to step 24. On step 23, with the 4 pin plugged up, I had 14 volts. On step 24, with the connector unhooked, I could put my red lead on pin 2 of the controller, and voltage would continuously drop from the 14 volt range all the way to 0 as though that pin was somehow energizing when plugged up, but wouldn't show voltage once unplugged. The chart says the controller is bad, too. Also: when spinning the motor over during testing, it started spinning fairly fast, and after 4 or 5 seconds started slowing down. I ran it probably 10 seconds, and it smoked a little. I could tell it was getting pretty hot. Is it bad to run it 10 seconds on 12 or 18 volts? Or is that motor weak or have a bad bearing or something dragging it down? I really appreciate the help.
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When you mentioned the hot solenoid diode I figured it was a bad controller.
The motor shouldn't have smoked when you tested it? Was it still bolted to the rear end? The open end of the motor has no support when it's not on the cart and you should never test a motor off of the cart unless you have some type of jig to support the shaft.
 
Thanks, HRC. No, I didn't have it bolted to the rear end. I didn't think about the support issue. Now I know.
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Nubs: Why did you think you better not? What were you going to say? If you were going to poke fun about something, you're more than welcome to; you certainly won't offend me! I never claimed to know everything about anything! I'm a pretty darn good mechanic, but I'm new to the cart world when it comes to this in-depth troubleshooting. I work on natural gas compressors up to 4000 hp daily, and I'm pretty familiar to ATVs and other small engines, but I've just branched into the in-depth carts within the last few months. I still have TONS to learn! I appreciate the help guys!
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sorry 06z, its not you. i very often pick a word out of a post and say some smart a$$ed thing
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it has nothing to do with your ability! i was just lookin' to bust Rods chops alittle
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again, i'm sorry if you thought i was pokin' at ya!
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