The Big Picture view of how a TXT cart works

[yurtle]

If it's a series, the controller doesn't know or care, whether you're going in forward or reverse - other than the 1/2 speed reverse, which can be disabled for troubleshooting - either by programming, or by simply disconnecting the 1/2 speed microswitch.

If it runs fine in reverse, it's not a controller, ITS, motor, battery, etc. issue. I'd look at the FNR as mentioned above.

[DaveTM]

Originally Posted by yurtle

If it's a series, the controller doesn't know or care, whether you're going in forward or reverse - other than the 1/2 speed reverse, which can be disabled for troubleshooting - either by programming, or by simply disconnecting the 1/2 speed microswitch.

If it runs fine in reverse, it's not a controller, ITS, motor, battery, etc. issue. I'd look at the FNR as mentioned above.

I'm not attempting to disagree with you, nor argue with you...but here is a picture of my "old" controller:



...and as you can see there is a "place" for a 1/2 speed wire (for reverse or I would assume even forward if you wanted) and this comes out of\into the controller. So, from what the poster is saying about his cart (runs fine in reverse, which is set up to run in 1/2 speed) but when run in forward, when the ITS is at 1/4, the cart get's a surge of max amps.

i suppose the ITS should be looked at as it's much cheaper and easy to look at, but the 1/2 speed still is controlled by the controller.

FWIW

Dave

[yurtle]

As I said, if you remove the 1/2 speed reverse option, and it still runs normal in reverse, but acts differently in forward, the controller, ITS, etc. can be ruled out. The controller and ITS don't know which direction the cart is told to run. The direction is changed by the FNR switching the direction of current flow in the motor wrt the rotor and stator windings.

[yurtle]

Found one. If you study the control voltage and the high current circuits, the two circuits you mention, besides the 1/2 speed reverse, the control voltage circuit is identical in forward and reverse. I doubt the 1/2 speed reverse is causing problems, but if it is, then it's a controller issue. I only mentioned it to rule out ANYTHING that is different in forward than reverse.

If you use this diagram for your AXE, troubleshooting a series cart is a breeze, since it's pretty easy to rule out one thing or another.

[DaveTM]

[remac]

I am concerned with the picture showing the CHG plug wire
that attaches directly to the solenoid - I do not see a fuse on that line.

Is there a fuse somewhere else that will blow if the CHG plug or line shorts?
My PDS has the CHG plug lead attach to the pack POS through a 50A fuse.
That way if I short the plug or the charge leads, the fuse blows.

[yurtle]

Agreed, but my stock series had NO fuses, either in the charging circuit, or the high current circuit.

[JohnnieB]

Fuses are fire protection devices.

They might prevent a cart from catching on fire if a short occurs, but are highly unlikely to prevent the electrical devices from be damaged.

For example: When I exploded a stock PDS motor, it took out the 400A controller, but the 250A fuse stayed intact.

------
The exposed terminals in a charge receptacle are tied directly to the battery pack's main positive and negative terminals and if anyone shorts them together, several hundred amps of current will flow, so it is a good idea the have a fuse in the cart's charge wiring if there are any kids around.

[DaveTM]

Originally Posted by yurtle

Agreed, but my stock series had NO fuses, either in the charging circuit, or the high current circuit.

If you were to "turn" the controller clockwise, you will see the main 400amp fuse on the high end circuit bolted on the controller right there. This is where the negative charge from the charger is attached to the fuse before the fuse is bolted onto the controller.

Dave

[yurtle]

I've replaced every cable, battery, controller, solenoid, FNR, you get the picture. There were no fuses.

It's possible the original owner removed it?