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Unread 12-10-2011, 08:59 AM   #41
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Default Re: Wire smoking.. Need HELP!!!

Ok... Test complete.

Run/Tow Switch - I set my multimeter to ohms and put connections on wires going in and out. The meter showed an open connection for both run and tow. So I assume that means it is bad.

Solenoid- I set my multimeter to dcv. Disconnected the pos(+) lead going to the controller. Black end was touching the negative battery lead, the red to the pos(+) lead going to the controller. I hit the gas pedel and did not get a voltage reading. I assume this also means the solenoid is bad.

My question is does that sound like I did the test correctly?
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Unread 12-10-2011, 10:00 AM   #42
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Default Re: Wire smoking.. Need HELP!!!

Not sure if you tested the switch correctly.
THe drawing below is how a SPDT ( single pole -double throw ) switchworks.
this type of toggles switch will have 3-flat terminals sticking out.

while the drawing is not exactly the layout of the inside rocker it mechanically illustrates how a switch functions.

Your meter must be set to read Ohms or continunity. First test the reading on the meter by touching BOTH test leads together ....you should get "0" ohms and when disconnected should go back to the resting point setting .
.

.

Disconnect switch before testing


Note when the handle of the switch is to the LEFT or to the right the connection is to the OPPOSIDE terminal.

THe center terminal ("C") is the common...it switches connection bewteen the "A"+"B" terminals..... place one of the meter leads here
Then with the other meter lead on the "A" or "B" terminal test for a "0" ohms reading (meaning good closed circuit) when the handle of the switch is in the appropriate position.
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Unread 12-10-2011, 10:12 AM   #43
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Default Re: Wire smoking.. Need HELP!!!

Quote:
Originally Posted by ForBruce View Post
this type of toggles witch will have 3-flat terminals sticking out
My run/tow switch only has two flat terminals coming out of the bottom.
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Unread 12-10-2011, 10:18 AM   #44
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Default Re: Wire smoking.. Need HELP!!!

then test as if only the "C" and "A" terminal is present

the main question is did you check the meter setup before you did the test
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Unread 12-10-2011, 10:28 AM   #45
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Default Re: Wire smoking.. Need HELP!!!

Oops... Forgot to disconnect the switch first. Retested with switch dissocnnected and it does work.

First tested meter, when two ends touched it read 0.0. When disconnected it read 0.L.

I hooked it up to the switch and at run it was 0.0, and at tow it was 0.L.
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Unread 12-10-2011, 10:51 AM   #46
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Default Re: Wire smoking.. Need HELP!!!

On the solenoid, I set my multimeter to dcv. Disconnected the pos(+) lead going to the controller. Black end was touching the negative battery lead, the red to the pos(+) lead going to the controller. I hit the gas pedel and did not get a voltage reading. I assume this also means the solenoid is bad. Did i test this right?
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Unread 12-10-2011, 11:18 AM   #47
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Default Re: Wire smoking.. Need HELP!!!

Quote:
Originally Posted by carnejm View Post
On the solenoid, I set my multimeter to dcv. Disconnected the pos(+) lead going to the controller. Black end was touching the negative battery lead, the red to the pos(+) lead going to the controller. I hit the gas pedel and did not get a voltage reading. I assume this also means the solenoid is bad. Did i test this right?
you tested the switch correctly.

the solonoid is a different approach.... when you step on the gas the solonoid should CLICK. Loud enough to be heard....no question if it is working.

second using the switch testing setting on the meter. remove the 2-SKINNY wires going to the solonoid including the DIODE. ( looks like a resistor with a BAR marking on it.... take a photo first so you don't mix up when you put it back..

now test the 2-small solonoid terminals for the "COIL" test ....again your meter should read a small ohms rating like about 10-50. if no reading the coil is burnted out and "OPEN CIRCUIT" ...
put wires back for next test .

jack up the rear of the cart ..so it cannot jump during the next test
(or just press gently on the gas)
with all wires including controller reconnected and tow/ run in run

set the meter to DC volts ( any scale of at least 50 volts)
the black negative lead of the meter goes to one of the SMALL solonoid terminals
the red plus (+) lead of the meter goes to the other SMALL solonoid terminal
gently step on the gas ..you should read 48 volts

if the meter reads minus voltage ( - 48 that is ok.... just means your plus and minus meter terminals are reversed on the meter ( or reversed on the solonoid )

my bet is you will read nothing because your controller is smoked
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Unread 12-10-2011, 11:47 AM   #48
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Default Re: Wire smoking.. Need HELP!!!

THanks ForBruce for the instructions!

Below are the results for the three tests.

Test .1
When I hit the gas pedel the first time it did click. But it did not click after that. Only the first time after you turn the cart on

Test .2
Disconnected two small wires from the front of the solenoid. I put the ohm meter to it and it read .230. ( just to note... Mine does not have a diode attached to it. Both small wires went into a wire harness.)

Test .3
With all wires reconnected, I sent my meter to dcv. Hooked the red end of the meter to the right small terminal on the front of the solenoid and the black end of the meter to the neg(-) lead of the battery. It read 49.8 volts. I did the same thing to the left small terminal on the front of the solenoid, it did not get a reading. (pre charge resistor got really hot again so I disconnected it pretty quick to avoid damage)

What does this all mean?
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Unread 12-10-2011, 12:16 PM   #49
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Default Re: Wire smoking.. Need HELP!!!

Retested #3 with revised instructions

Cart on and in run. All wires connected. Multimeter set to dcv. Red lead to one of the front small terminals and the black to the other. Voltage read -48volts. The thing is that it reads this without pushing the gas.

Again pre charge resistor was burning so I disconnected very quickly.

I did also check to see if voltage was flowing to the controller via the left large terminal on top, but it wasn't.
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Unread 12-10-2011, 01:09 PM   #50
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Default Re: Wire smoking.. Need HELP!!!

It means your controller has moved on to a better place



one more check --batteries disconnected
disconect one HEAVY wire off the solonoid and check for continunity BETWEEN 2-LARGE TERMINALS.
a good solonoid will give no reading ( OL on meter ) a bad solonoid (contacts WELDED CLOSED ) will show "O" ohms.

this test is only for the solonoid..you still have a bad controller..which i would replace with an alltrax programmable type.
call me if you like 917-685-8902
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