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Old 10-23-2012, 04:57 PM   #1
slimpiking
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Default 96 txt series wiring diagram

I need wiring diagram to verify /test circuits dealer sold me a new controller said it would fix problem. had motor tested it was fine but cart still doesn't move.
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Old 10-23-2012, 05:58 PM   #2
Bowslayer
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Default Re: 96 txt series wiring diagram

Look in the stickies above your thread and you should find it.
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Old 10-23-2012, 09:07 PM   #3
slimpiking
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Default Re: 96 txt series wiring diagram

I found 96 wiring diagram and verified cart is wired correctly. solenoid clicks controller new-motor professionally tested dealer no help what so ever. Tested fwd/rev switch seems I always have power to S1 and S2 at the same time. Wiring diagram says this is fwd & rev wires. Don't know what's up seems like I'm somehow cancelling out my motor? ANY suggestions would be helpful
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Old 10-24-2012, 06:43 AM   #4
JohnnieB
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Default Re: 96 txt series wiring diagram

If the motor is not spinning, you will have the same voltage on S1 and S2.

All the cables, contacts, connections and components that are used in Forward are also used in Reverse, so there actually aren't any forward or reverse cables.

The only difference between forward and reverse, is the direction the electrical current flows through the Stator.
(Note: In earlier series carts, the current through the armature was switched.)

-------------------
Since the solenoid is clicking, the problem is in the high current loop someplace.

Jack the rear wheels off ground and put on jack stands so half ton cart doesn't take off unexpectedly and run over someone or something.
Then connect your DVM's negative test lead to B- terminal on top of controller and the positive test lead to the M- terminal.

With charger cable unplugged from cart, Keyswitch ON and F/R switch in F, press throttle pedal until solenoid first clicks.

The DVM should read full battery pack voltage.

If not, move the DVM's positive test lead progressively to test points closer to the main B+ terminal on the battery pack.
When you find the voltage the problem will be between that point and the previous one that did not have the voltage.

Here is a series cart schematic with the high current loop traced.

-----------
If the full battery pack voltage is between B- and M-, we'll have to troubleshoot further.
Attached Images
File Type: jpg Wiring Diagram - Series- Hi-Current traced.JPG (59.3 KB, 0 views)
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Old 10-24-2012, 11:56 AM   #5
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Default Re: 96 txt series wiring diagram

I'll try it and get back in a day or two. Out of area today
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Old 10-25-2012, 03:45 PM   #6
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Default Re: 96 txt series wiring diagram

Did your test on B-& M- Full Voltage / dropped off to 21.00 pedal depressed. Double checked wiring and everything is right. Did M- & B+ No initial voltage / solenoid clicks still no voltage. Did all the ITS Tests to controller and all the wires and voltages checked out. Also checked the fwd/rev switches and the power to the terminals when lever is moved. Checked motor continuity between S1-S2 & A1-A2. No continuity between either A or S circuits. Had it between A1-A2 and S1-S2 only. If I disconnect M- from controller I had Full voltage from A1 wire. Like I said New Controller From EZGO and I'm stumped. Any other suggestions?
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Old 10-25-2012, 04:47 PM   #7
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Default Re: 96 txt series wiring diagram

Quote:
Originally Posted by slimpiking View Post
1. Did your test on B-& M- Full Voltage / dropped off to 21.00 pedal depressed.............
2. Did M- & B+ No initial voltage / solenoid clicks still no voltage.
3. Did all the ITS Tests to controller and all the wires and voltages checked out.
4. Checked motor continuity between S1-S2 & A1-A2. No continuity between either A or S circuits. Had it between A1-A2 and S1-S2 only.
5. If I disconnect M- from controller I had Full voltage from A1 wire.
6. Like I said New Controller From EZGO and I'm stumped. Any other suggestions?
1. Indicates Controller isn't turning on all the way. (Throttle input? See # 3 below)

2. Should be zero when solenoid clicks and then should smoothly rise to full battery pack voltage as pedal is slowly pushed to floor .
What is voltage with the pedal down?

3. What is the voltage on Pin-2 (Black wire) with connector plugged in?
Should be slightly more than 14V, but less than 15V.
What is the voltage on Pin-1 (White wire) with connector plugged in?
Should be 0.45V to 0.53V when solenoid first clicks and 1.5V or over when pedal is down.

4. Did you measure from Motor Case to the A studs and the S studs?
Unless it is a new motor or has just been taken apart and thoroughly cleaned, there will be some carbon dust from the brushes and the carbon track will read on an Ohms X 1Meg or higher scale.

5. There would be no current flow, so full battery pack voltage would be measured.

6. Receiving new parts that don't work isn't a unique experience.
I'm not saying the controller is bad, just that it is a possibility.

Hang in there, we are on the home stretch.
There is voltage missing in step 1 and might be in step 2, so it is just a matter of tracking it down.
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Old 10-26-2012, 11:33 AM   #8
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Default Re: 96 txt series wiring diagram

Yes I tested all 4 wires out of controller. Black wire 14.05 pedal depressed. White wire .51 initially ramps up to 1.53 pedal depressed. Red wire voltage when pedal depressed orange wire at voltage. No voltage across motor case from A or S terminals. M- & B+ test no initial voltage-solenoid click still no voltage as pedal is depressed.
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Old 10-26-2012, 12:49 PM   #9
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Default Re: 96 txt series wiring diagram

Quote:
Originally Posted by slimpiking View Post
Yes I tested all 4 wires out of controller.
1. Black wire 14.05 pedal depressed.
2. White wire .51 initially ramps up to 1.53 pedal depressed.
3. Red wire voltage when pedal depressed
4. orange wire at voltage.
5. No voltage across motor case from A or S terminals.
6. M- & B+ test no initial voltage-solenoid click still no voltage as pedal is depressed.
1.
2.
3.
4. Orange wire is half speed reverse. Should only have voltage when F/R is in R.
5. I was asking if there was any continuity (Ohms) between the A & S studs and motor case.
6.
a. We got full battery pack voltage between M- and B- when the solenoid clicked, so the High current loop is complete (Has continuity).
b. The throttle test good, so the controller is being told to pass amps to the motor.
c. There is no voltage between M- and B+ when pedal is pushed to floor, so the controller is not doing what it is being told to do.

Conclusion: The controller is bad.
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Old 10-26-2012, 12:58 PM   #10
blewis46580
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Default Re: 96 txt series wiring diagram

What is battery pack (reference voltage) and what is it when accel pedal is depressed? Are you getting reference voltage to speed controller?
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