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Old 01-26-2017, 11:26 AM   #1
Coon Urine
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Default 2006 TXT Solenoid Diode

Before my father n law gave me this cart he had changed the solenoid. He said as soon as he turned the key on the solenoid started smoking. So he turned it off. As I'm tearing everything down I've noticed that the stripe on the diode is actually hooked up backwards (small negative post) on the solenoid. Would this have caused the immediate smoke, also what other damage could this have caused. He ended up just buying another cart, and giving me this one. I like projects
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Old 01-26-2017, 11:31 AM   #2
Coon Urine
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Default Re: 2006 TXT Solenoid Diode

Am I correct on what I'm seeing?
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Old 01-26-2017, 11:47 AM   #3
JohnnieB
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Default Re: 2006 TXT Solenoid Diode

The diode is backwards, but that won't make the solenoid smoke. Perhaps the smoke was from the diode instead.

The diode is shorting the battery pack's B+ to B- via a few feet of wire and four sets of switch contacts. The pedal microswitch is typically the one taken out by a diode that has been installed backwards, but it could be any or all of them, or none.

For testing and troubleshooting, you can just leave the diode disconnected.

Here is a schematic with the circuit highlighted.
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File Type: jpg Wiring Diagram - Series with KSI traced.JPG (58.9 KB, 0 views)
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Old 01-26-2017, 11:56 AM   #4
Coon Urine
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Default Re: 2006 TXT Solenoid Diode

Quote:
Originally Posted by JohnnieB View Post
The diode is backwards, but that won't make the solenoid smoke. Perhaps the smoke was from the diode instead.

The diode is shorting the battery pack's B+ to B- via a few feet of wire and four sets of switch contacts. The pedal microswitch is typically the one taken out by a diode that has been installed backwards, but it could be any or all of them, or none.

For testing and troubleshooting, you can just leave the diode disconnected.

Here is a schematic with the circuit highlighted.

Thanks JohnnieB, I'm still trying to digest these wiring diagrams so bare with me. It may take me a few days to reply beings I can only work on it late afternoons for a few hours.
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Old 01-26-2017, 12:01 PM   #5
Coon Urine
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Default Re: 2006 TXT Solenoid Diode

Do you think it fried the solenoid?
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Old 01-26-2017, 12:55 PM   #6
scottyb
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Default Re: 2006 TXT Solenoid Diode

This is a common DIYer error. Installing the diode backwards shorts out the solenoid activation circuit not the solenoid. Sometimes removing the diode will allow the solenoid to engage & the cart to run, in this case replace the diode paying close attention to the install instruction, like banded end towards the (+) side or red wires in this case.

If the solenoid will not engage with the diode removed it is likely the pedal box micro switch has fried like a fuse. Get the proper ms with the roller on the trigger and a new diode.
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Old 01-26-2017, 02:33 PM   #7
Coon Urine
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Default Re: 2006 TXT Solenoid Diode

Quote:
Originally Posted by scottyb View Post
This is a common DIYer error. Installing the diode backwards shorts out the solenoid activation circuit not the solenoid. Sometimes removing the diode will allow the solenoid to engage & the cart to run, in this case replace the diode paying close attention to the install instruction, like banded end towards the (+) side or red wires in this case.

If the solenoid will not engage with the diode removed it is likely the pedal box micro switch has fried like a fuse. Get the proper ms with the roller on the trigger and a new diode.
Thanks Scottyb! I'll try it out.
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Old 01-27-2017, 09:56 AM   #8
Coon Urine
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Default Re: 2006 TXT Solenoid Diode

Before buying any parts I was doing the electrical diagnostics from the sticky. So far this is what I have.

Battery Pack = 37.07 volts (Old batteries not fully charged)
Batt - / Solenoid + = 37.08 volts
Batt - / Controller side of solenoid = 34.15 (Starts @ 36v then drops rapidly)

That's the furthest I got this morning before work. Anything wrong so far?
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Old 01-27-2017, 11:56 AM   #9
Coon Urine
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Default Re: 2006 TXT Solenoid Diode

TTT
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Old 01-27-2017, 12:34 PM   #10
JohnnieB
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Default Re: 2006 TXT Solenoid Diode

Quote:
Originally Posted by Coon Urine View Post
Before buying any parts I was doing the electrical diagnostics from the sticky. So far this is what I have.

Battery Pack = 37.07 volts (Old batteries not fully charged)
Batt - / Solenoid + = 37.08 volts
Batt - / Controller side of solenoid = 34.15 (Starts @ 36v then drops rapidly)

That's the furthest I got this morning before work. Anything wrong so far?
If you get 34.15V before the solenoid clicks, it is normal. If it is after the solenoid clicks, you have a bad solenoid.

After the solenoid clicks (contacts close) the voltage on both large terminals should be the same.
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