96 EZ Go TXT Electric- Will Not go, either direction

ranchking01

96 TXT with Electronic speed control. Manufacturers code 80196. Was running fine several weeks back upon last use. Now will not move forward or reverse. Batteries are fully charges and verified with Hydrometer. All connections clean and tight.

Attempting to drive, tried in forward and reverse several times, but would not move, only got 1 initial click of solenoid, with repeated pushes on accelerator pedal. Solenoid was very hot to touch. Assumed it was bad so replaced it.
Removed and reconnected wires on solenoid one at a time so I'm sure they are exactly correct as before replacement.
Went to reconnect batteries after solenoid replacement and connection at battery sparked heavily as if direct short.
Noticed part #6 in wiring manual, "resistor" that connects to both sides of the solenoid seemed burned from long ago. Removed one side of resistor connection from Solenoid and sparking/short did not re occur when reconnecting battery. There is no continuity thru the resistor.

However, still unable to get cart to move.

What is purpose of resistor wire and why did system appear to have short when it was connected to both sides of solenoid. What else should be checked i trouble shooting process to get golfcart to drive again.?

Thank you

BGW

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JohnnieB

1. There are a bunch of filter capacitors in the controller and the resistor allows them to "Precharge" to reduce the inrush of current when the solenoid contacts close. Cart will run without it, but the solenoid contact will suffer, so it should be replaced with a good one (250 Ohms 5 Watts)

2. Sounds like you might have more than one problem.
You say the batteries are good, so first, get the solenoid to click every time pedal is pushed. Here is a schematic with KSI circuit traced out in red (B+) and Green (B-)

Second, trace out the high current circuit. Here's a generic drawing without the KSI wiring.

Attached Images

	Wiring Diagram - Series with KSI traced.JPG (58.9 KB, 4 views)
	Hi Current Circuit - Series Motor - EDITED.JPG (63.6 KB, 3 views)

scottyb

It sounds like you may have a bad motor or controller or both... is the old solenoid welded shut? If not, it did not need replacing.

I would test the motor for unwanted continuity. (looking for a short)
Mark and disconnect all four cables at the motor (use 2 wrenches at a time at each stud to prevent stud from spinning)
Continuity okay between both A terminals and both S terminals but no continuity between any A and any S terminal.
If motor tests okay for continuity, it's likely you need a new speed control. Time for an upgrade