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Unread 07-15-2016, 08:23 AM   #1
Gone Wild
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Default Help Identify Solenoid Problem?

I have a 1993 Club Car DS with following upgrades:
48V
FSIP 700 amp controller
400 amp solenoid
potentiometer
Heavy duty F&R switch
4" lift
23" tires

My battery pack is fully charged both per voltmeter and installed digital voltmeter. However, I get no click from the solenoid. After measuring the voltage and the two small connections on the solenoid, it does not have full voltage. Using the tests I found on this forum, I've determined that the negative is "missing." The negative is attached to the B- post of the controller. I can't find any loose connections at the controller.

I've searched here an elsewhere and not come up with any ideas when the negative side is missing. If you can help, I'd appreciate it. Thanks.
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Unread 07-15-2016, 08:43 AM   #2
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Default Re: Help Identify Solenoid Problem?

Are You saying that when You measured from pack positive to the small negative post you had 0v?

If so, the negative wire to B- is broken or you have a fuse on pack negative that is blown.
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Unread 07-15-2016, 08:51 AM   #3
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Default Re: Help Identify Solenoid Problem?

+1 to what Sergio said.

Could post pics of your wiring and solenoid? It might help better diagnosis the problem.
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Unread 07-15-2016, 09:30 AM   #4
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Default Re: Help Identify Solenoid Problem?

Also note the large terminal & the silver colored base of the MZJ400 solenoid is energized and the small negative wire in question may be shorted out on this (+) base ?
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Unread 07-15-2016, 11:39 AM   #5
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Default Re: Help Identify Solenoid Problem?

Will post pics, but wiring done as described here:

http://www.cartsunlimited.net/troubl...ion-kit--.html
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Unread 07-15-2016, 11:56 AM   #6
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Default Re: Help Identify Solenoid Problem?

Please verify how exactly did You test it to come up with "negative side is missing".
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Unread 07-18-2016, 05:54 PM   #7
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Default Re: Help Identify Solenoid Problem?

Sorry for the slow response - been out of town for a few days. The procedure I used was:

I connected the black negative lead from the voltmeter to small terminal on the solenoid that was negative and the red lead of the voltmeter to the positive post of the first battery in the series. I then turned on the key and pressed the accelerator. Nothing.

On the other hand, the reverse shows system voltage. When I connect the red lead of the voltmeter to the small positive post on the solenoid and then connect the black to the negative battery post, then, I get full system voltage.

Here is a picture of the solenoid, if it goes through:

IMG_3616.jpg

One other thing. Cart is wired as set out in the diagram here and has been for a couple of years:

6fc4c83ad757ef50cb6fdbaace4ca9e6.jpeg
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Unread 07-18-2016, 06:03 PM   #8
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Default Re: Help Identify Solenoid Problem?

Quote:
Originally Posted by MyCousinVinnie View Post
Sorry for the slow response - been out of town for a few days. The procedure I used was:

I connected the black negative lead from the voltmeter to small terminal on the solenoid that was negative and the red lead of the voltmeter to the positive post of the first battery in the series. I then turned on the key and pressed the accelerator. Nothing.

On the other hand, the reverse shows system voltage. When I connect the red lead of the voltmeter to the small positive post on the solenoid and then connect the black to the negative battery post, then, I get full system voltage.

Here is a picture of the solenoid, if it goes through:

Attachment 138842

(in red) Is this the same as the battery main where you would measure the total pack voltage?

If yes and not (-) voltage can you put a small wire from the (-) solenoid post to the Controller B- or battery pack main (-) and see if the cart runs?
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Unread 07-18-2016, 06:17 PM   #9
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Default Re: Help Identify Solenoid Problem?

It is the same battery post that I would consider to be the first one in the series where I would measure it. It is where the wire comes in from the charger receptacle and the first one in the series per one of your diagrams.

There is already a wire from the solenoid to the B- on the controller, so I don't understand the request. Are you saying you want a wire from the negative pack directly to the controller?
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Unread 07-18-2016, 07:12 PM   #10
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Default Re: Help Identify Solenoid Problem?

Measure between pack positive and Controller B-, You should get +48v, no need to turn key ON or press pedal.

If You do, the only explanation is that the wire current connected to the negative small solenoid post is not making a connection all the way to Controller B-.

You should check the crimp connections or just replace the wire from solenoid to Controller B-.
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