99 ezgo conversion HELPPPP lol

[0chocinc01916]

Alright guys. I hit a road block. Have a 99 36v TXT series. Bought everything for a 48v conversion plus motor solenoid and HD Fnr switch. Got most of the way through it and came to the final stages of wiring it up...
D&d motor
Sr 48500 alltrax

First thing. Bought a new 48v charger receptacle. And the wires aren't long enough to reach the end of the battery pack? Also which wires go where?
Also there is a 3rd prong on the FNR switch that said its suppose to connect to the charger port?

Secondly. On the controller.. I have it wired as follows
oem orange wire to blue terminal
Oem white to j4
Oem red going to solenoid and then red jumper to red terminal.
The black is where I'm lost. The manual says OEM black to J5 and then black wire from solenoid to black terminal on controller. The FNR buzzer has a black wire as well. Does that jump to the solenoid like I have it and then to the controller?

Sorry the wires are kinda messy. Still gotta clean it up.

[Andy4639]

The first thing I would do is turn that solenoid right side up. If it sticks it can't cut off by gravity upside down. Right side up the weight should make it drop out if you loose power.
Here is the schematic you need.

[JohnnieB]

Charge receptacle wiring:
Red wire - Battery pack's main positive terminal.
Black wire - Battery pack's main negative terminal.
Gary cable with black box at end - Temperature sensor, Not an electrical connection, can go on any convenient terminal.
Blue wire - Goes to MS-2 in FNR switch

Secondly. On the controller.. I have it wired as follows
oem orange wire to blue terminal -
Oem white to j4 -
Oem red going to solenoid and then red jumper to red terminal.
The black is where I'm lost. ---- There are THREE separate black wires
1. Black wire on J5 comes from ITS sensor, ONLY.
2. Black wire from reverse beeper goes to B- terminal on controller.
3. Black wire from solenoid coil goes to Black push on jack.

[0chocinc01916]

Originally Posted by JohnnieB

Charge receptacle wiring:
Red wire - Battery pack's main positive terminal.
Black wire - Battery pack's main negative terminal.
Gary cable with black box at end - Temperature sensor, Not an electrical connection, can go on any convenient terminal.
Blue wire - Goes to MS-2 in FNR switch

Secondly. On the controller.. I have it wired as follows
oem orange wire to blue terminal -
Oem white to j4 -
Oem red going to solenoid and then red jumper to red terminal.
The black is where I'm lost. ---- There are THREE separate black wires
1. Black wire on J5 comes from ITS sensor, ONLY.
2. Black wire from reverse beeper goes to B- terminal on controller.
3. Black wire from solenoid coil goes to Black push on jack.

The little tiny 16g black wire goes to b- ? I was told by the vendor absolutely NO small wire goes to big terminals on controller lol. Now I'm even more confused

[Andy4639]

All you have to do is follow the drawing I posted. It's pretty simple.

[tsmith_co]

Originally Posted by Andy4639

All you have to do is follow the drawing I posted. It's pretty simple.

I would personally follow rev A or B of that diagram - which is just a minor change. Wiring this way, your Forward and Reverse will be opposite.

Original cart wiring, and also Rev A and B of this diagram show:

M- to A1 (not A2 like here)
A2 to C on FNR (not from A1 like Rev C)

I originally wired according to Rev C and forward and reverese backwards - everything else wired properly. Switched the 2 listed above to follow the Rev A and B wiring (and original ezgo wiring) and everything was perfect!


Also, looks like you are doing exacly what I did! 36v to 48v conversion, sr48500 controller, etc. I kept the original 36v motor for it's torque!
https://tsmith.co/golf-cart-project/

[JohnnieB]

Originally Posted by 0chocinc01916

The little tiny 16g black wire goes to b- ? I was told by the vendor absolutely NO small wire goes to big terminals on controller lol. Now I'm even more confused

The black wire from the beeper goes to B-.
The B- terminal on the controller is connected to the B- terminal on the battery pack by a 4ga or thicker cable.
Connect the black wire from the beeper to one end or the other of that cable and find a vendor that knows something about reading schematics.

Attached is the A version of the Alltrax SR in a TXT schematic in a more readable format.