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Old 03-31-2012, 10:08 PM   #1
EricPicou28
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Default 1996 EZ-GO Series Kart (Completely Dead)

hello to all !! New to Buggies Gone Wild! My first post.

I'm not new to karts i have been haveing a cart for some time now and know a little bit about them. I have a 1996 EZ-GO (TXT) (SERIES) kart with all stock parts. I fully charged the battery pack and have 38 volts comming from the battery pack. I also have 38 volts at the solinoid on the battery pack side but NOTHING on the controler side of the solinoid. The cart is completely dead will not go at all no solinoid click nothing!! Please Help!! Thanks your time in advance.
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Old 04-01-2012, 10:10 AM   #2
JohnnieB
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Default Re: 1996 EZ-GO Series Kart (Completely Dead)

Welcome to BGW!

Sounds like you have two problems.
Easy one first.

You've got B+ (Battery Pack Voltage) on battery side of solenoid main terminals, but nothing on other side.
You should have B+ on battery side and B+ less 3 to 5 volts or so on controller side.

Either the Precharge Resistor (250 ohm shown on schematic) is missing or open.
Resistor is not need to run, it just saves some wear and tear on the solenoid contacts.

Now let's tackle the Solenoid not clicking issue.

Here's a schematic for a series cart with the solenoid activation circuit traced in Red from B+ to one side of solenoid coil and in green from other side of coil to B-

1. B+ starts at Positive Radsok in cart's charger receptacle.
2. Goes through Reed Switch. (labeled Ignition Interlock on schematic)
3. Goes through MS-2 on F/R assemble.
4. Goes through Keyswitch.
5. Goes through MS-3 in Throttle box.
6. Goes through Solenoid coil
7. Finishes at B- terminal on controller.

.
Attached Images
File Type: jpg Wiring Diagram - Series with KSI traced.JPG (58.9 KB, 0 views)
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Old 04-02-2012, 08:40 AM   #3
EricPicou28
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Default Re: 1996 EZ-GO Series Kart (Completely Dead)

Thanks for you help..... I have checked my wireing and it all looks right. Also I have no juice at the controller either. What parts could be bad causeing this? Controller?? Also should i connect the red wire from the charger box to the positive on the battery pack to by pass the reid switch? Thanks, Eric
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Old 04-02-2012, 09:50 AM   #4
JohnnieB
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Default Re: 1996 EZ-GO Series Kart (Completely Dead)

Quote:
Originally Posted by EricPicou28 View Post
..............
1. I have checked my wireing and it all looks right.
2. Also I have no juice at the controller either.
3. What parts could be bad causeing this?
4.Controller??
5. Also should i connect the red wire from the charger box to the positive on the battery pack to by pass the reid switch?
..........
1. Looks are deceiving. A DMM is your friend.
2. The solenoid has to activate (Click) to get "Juice" to the controller.
3. The solenoid coil, 4 switches and the wires connecting them in a series circuit.
4. Troubleshooting the controller comes later. We are still trying to get power to it. (IE: Getting solenoid to click)
5. If you measure B+ on the smaller of the three wires coming out of the charger receptacle, the Reed switch is good.
The next step is to measure voltage at MS-2, then at Key Switch, then at MS-3. Etc.
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Old 04-02-2012, 05:45 PM   #5
EricPicou28
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Default Re: 1996 EZ-GO Series Kart (Completely Dead)

ok guys heres the latest,

Battery Pack 37 volts
White wire in charger box 37
Key switch 37
Solenoid on battery side 37 controller side 36. On the controller i have 36 at M- and 36 at B-. On the F & R micro switches (switch on drive side at the blue wire 37 on the red wire 37. Also have 36 volts on all 4 copper lugs on the F & R.

Still no CLICK of the solenoid!!!

I noticed on the plastic plug containing white,black,red and green wire the male and female plugs didnt look to great. Can i do away with the plug and use but conectors?

What's next? I feel like we are getting close. Thanks in advance.

Eric
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Old 04-03-2012, 05:05 AM   #6
JohnnieB
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Default Re: 1996 EZ-GO Series Kart (Completely Dead)

Quote:
Originally Posted by EricPicou28 View Post
ok guys heres the latest,

Battery Pack 37 volts
White wire in charger box 37
Key switch 37
Solenoid on battery side 37 controller side 36. On the controller i have 36 at M- and 36 at B-. On the F & R micro switches (switch on drive side at the blue wire 37 on the red wire 37. Also have 36 volts on all 4 copper lugs on the F & R.

Still no CLICK of the solenoid!!!

I noticed on the plastic plug containing white,black,red and green wire the male and female plugs didnt look to great. Can i do away with the plug and use but conectors?

What's next? I feel like we are getting close. Thanks in advance.

Eric
One step at a time.
Until the solenoid clicks, the information highlighted in RED is meaningless and may cause confusion.
(Well, it is not 100% meaningless, it tells us the solenoid isn't activated, but we already know that.)

The pertinent information highlighted in BLUE buried between the meaningless information in RED, tells me you have completed Step #3 in the 7 troubleshooting steps I originally posted.

Next, look for B+ going to and coming from Key switch.
Then B+ going to and coming from microswitch located in ITS box.
Etc.

Also, charge the batteries. At 37V, the plates are sulfating as we speak.
Troubleshooting should be done with fully charged batteries (38.2V or higher)

As for the connector, Let's fix the solenoid not clicking first.
Maybe some contact cleaner later, but don't remove the wires from the nylon plug.
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Old 04-03-2012, 10:35 PM   #7
EricPicou28
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Default Re: 1996 EZ-GO Series Kart (Completely Dead)

WOW!! what a great site this is. Thank you JohnnieB, the kart is up and going strong. I had no power at the microswitch in the ITS box. I changed the switch and was good to go.
Thanks again,
Eric
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