I screwed up! (electrical)

prdmetalworks

Quick background - I own a metal fabrication shop & am pretty mechanically inclined. I am just completing a full rebuild on a 2002 TXT series cart for a good friend. This is kind of like a pimp my cart thing, I was given a budget & the owner has no idea what they are getting.
I am supposed to deliver the cart on Friday & thought I was doing pretty good with the schedule being that I only have a couple hours of wiring & a good polishing left to do.

The problem: I went to replace the factory battery meter with a digital volt meter & long story short, grounded out one of the 36v wires on the back of the ignition.

I know absolutley nothing about electric carts (except for the fact that I should have unhooked the battery) and am supposed to deliver in 2 days!!! None of the 12v accessories have been affected, I have 38.7v on the pack, but nothing when you hit the throttle.

What did I burn up? I can't find any fuses, so I'm thinking the diodes on the solenoid, or the solenoid itself? Any (quick) help would be appreciated!

BGW

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yurtle

Hmm. The good news is I doubt you hurt the solenoid, controller, or motor. If you happened to blow the diode (doubtful) it would still work, but you'd eventually need to replace.

I like this wiring diagram, though there are others that you may be used to.

Hook up your negative lead to the pack negative and find where you lose voltage. I'd start with the reed switch. Then MS2 and the keyswitch. Everything downstream would probably be unaffected, though there may have been a surge. If you have voltage going through the keyswitch, you can check MS3, then finally pin 1 on the controller.

You also may want to unplug and replug the 4 wire Molex connector that goes to the throttle box.

Attached Files

Doc100-043-B_DWG-AXE-EZGO-Wire-Dia.pdf (174.3 KB, 0 views)

yurtle

There are two ways to check MS3. You can pretty much go straight to pin 1 on the controller with the pedal pressed just a little. Place on jack stands first. Alternatively, you can disconnect the 4 wire Molex connector and test for continuity. The wire colors on mine match the diagram.

prdmetalworks

Would that diagram work with an 02' as well? It says it's for 94-2000

yurtle

I can't say for sure, but I doubt if anything changed significantly. I do know they eventually stopped using a reed switch and use a fuse instead. Either way, I'd start there. Then see if you have juice at controller pin 1. That's a quick and easy check.

If you have it at the reed switch/fuse but not on pin 1, then it's something in between. You can ignore MS4, since that doesn't prevent it from running. If you have voltage coming out of MS3, that should power the controller and actuate the solenoid.

scottyb

I think this cart had a reed switch which is presently ready for a free 1 minute bypass and away you go! I hope.

Anybody who saved my reed switch bypass pic? Please post it.

yurtle

Here's one I found.

I cut my white wire close to the reed switch and crimped on a ring terminal. You could also strip it, twist the wire strands, then bend it into a loop and tin it with solder.

Attached Images

Ezgo Reed Switch Bypass.jpg (169.2 KB, 0 views)

yurtle

If you use the diagram I sent you, ignore the "* add this fuse" and * add this diode" on the top of the diagram. The reed switch is labeled "interlock".

prdmetalworks

I've been checking out a few things. Keep in mind I'm pretty limited as to knowing what the hell I'm doing!
The ignition switch is operating as it should.
The little micro switch by the inductive throttle deal has power until the throttle pedal is depressed & power switches off.
I have power on both big lugs on the solenoid? I thought I'm only supposed to have power on one side until one of the little "trigger" wires tells the solenoid to contact & send power to the other big lug?
As far as the MS switches, I have no idea what I am looking for.

prdmetalworks

I didn't realize there were more reply's before I replied. I was going to say I couldn't find the reed switch either, but that pic explains that. I'll give that a shot & report back.
Thanks for all the help guys