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Old 10-13-2012, 01:30 PM   #1
Taykol
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Default 99 ezgo no click after quick spark

1999 Ezgo TXT K299 1217526
Picked up a week or two ago. Only small problem was running very slow in forward and slightly faster in reverse. Pulled out the orange wire= Full speed forward, full speed reverse.
Tried to 'fix' that problems by plugging a spare black wire into previous orange wire spot.
As you can see in photo of f+r switch, there is a loose black and orange wire next to a fried hookup. That is where I plugged the black into and it popped and smoked when I hit the gas to 'test' it. Now there is no click or movement for this ezgo. Any help would be greatly appreciated!


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Old 10-13-2012, 03:40 PM   #2
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Default Re: 99 ezgo no click after quick spark

Roady89 said this years ago-

Re: 99 Ez go, works forward not in reverse
There is no black wire that goes to MS4. There is only an Orange and a Red. The only black around MS4 in the diagram is for the back up buzzer's ground connection. If you hooked that black to MS4 when you put it in reverse you cause a direct short. The fact of the matter is the cart is NOT wired correctly. There is no other explanation for this. They do not just burst into flames for no reason.

what exactly would this short? Just the micro switch, ms4?
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Old 10-14-2012, 07:59 AM   #3
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Default Re: 99 ezgo no click after quick spark

The black wire may have been the reverse buzzer - supply from the solenoid, unfortunately it shares the solenoid terminal with the controller - supply to the solenoid.
So a direct short would have taken the controller out.
Attached Images
File Type: jpg Ezgo Series solenoid activation diagram.jpg (107.9 KB, 0 views)
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Old 10-14-2012, 08:15 AM   #4
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Default Re: 99 ezgo no click after quick spark

From what I researched it was the buzzer wire. If that terminal did get fried is there a way to isolate the controller to test it. The cart isn't worth a new controller.
Was hoping I just blew the solenoid...
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Old 10-14-2012, 09:37 AM   #5
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Default Re: 99 ezgo no click after quick spark

You might have lucked out and just taken out some switches.
If you connected the black wire that originally went to beeper, you connected B- directly to B+through a bunch of switches when the pedal switch closed.

In your first post, you said cart went faster in reverse than in forward, so the F/R switch is actually in R when it is going forward. Meaning both MS-2 and MS-4 are closed.

The schematic Scotty posted has the solenoid activation circuit traced.
I suspect, one or more of the switches and/or wires are burnt out.
(Reed switch, MS-2, Keyswitch and MS-3, and the wire connecting them)

Get the solenoid clicking when it is supposed to, before checking the controller.

BTW - once it is going again, reverse the cables on the F/R switch B and D terminals to get F and R back in sync.
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Old 10-14-2012, 11:36 AM   #6
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Default Re: 99 ezgo no click after quick spark

Scotty and Johnnie, thank you for the help so far.
Let me try and give some more info to help isolate the problem.
There is 38.3 coming from B+
38.3 coming from battery side of solenoid.
Controller side of solenoid just jumps around on DMV like there is no reading.
38.3 coming from white wire of charger receptacle (so reed switch is not problem?)
It seems as though I need to get a solenoid click in order to test the possible burnt switches. Is the next step to jump solenoid to make sure I didn't burn it up? Please let me know next step or if more readings are needed. Thanks again!
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Old 10-14-2012, 12:51 PM   #7
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Default Re: 99 ezgo no click after quick spark

Quote:
Originally Posted by Taykol View Post
Scotty and Johnnie, thank you for the help so far.
Let me try and give some more info to help isolate the problem.
There is 38.3 coming from B+
38.3 coming from battery side of solenoid.
Controller side of solenoid just jumps around on DMV like there is no reading.
38.3 coming from white wire of charger receptacle (so reed switch is not problem?)
It seems as though I need to get a solenoid click in order to test the possible burnt switches. Is the next step to jump solenoid to make sure I didn't burn it up? Please let me know next step or if more readings are needed. Thanks again!
You've got it backwards. The burnt switches will prevent the solenoid form clicking.

It is a series circuit, and the voltage has to pass through all of the switches I listed to activate the solenoid.
It's like the old Christmas tree lights, when one bulb burnt out, they all went out.

If there is pack voltage on the small white wire coming out of the charger receptacle, the reed switch is okay.

Next place to check for pack voltage is the Red wire on MS-2 (mounted on F/R assembly), then the Blue wire from MS-2 to the Keyswitch, then the green wire from Keyswitch to MS-3, and so on.
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Old 10-14-2012, 01:05 PM   #8
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Default Re: 99 ezgo no click after quick spark

Quote:
Originally Posted by JohnnieB View Post
It's like the old Christmas tree lights, when one bulb burnt out, they all went out.
I'm not sure how many folks remember series lights. I'm a youngster at 50 and never had to endure the experience. Everything I grew up with was parallel.
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Old 10-14-2012, 02:05 PM   #9
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Default Re: 99 ezgo no click after quick spark

Quote:
Originally Posted by yurtle View Post
I'm not sure how many folks remember series lights. I'm a youngster at 50 and never had to endure the experience. Everything I grew up with was parallel.
You missed the joyful experience of taking a known good bulb and pluggin it into 50-75 sockets to find the burnt bulb, then?
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Old 10-14-2012, 02:21 PM   #10
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Default Re: 99 ezgo no click after quick spark

always fun being up on a ladder with gloves unscrewing bulbs... thanks for the diagram.. just sent it to my phone so I can correctly wire my key up.
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