95 Ezgo 36v shuttle 6 solenoid clicks wont move

tmaxx2007

Hi All, I have a 95 Ezgo Shuttle 6 36v that the solenoid clicks when pedals pushed, tries to move then nothing. Got 38v, all terminals are clean and tight. checked pot meter 0ohms at rest gradually goes to 5.48ohms at WOT. Tries jumping solenoid nothing. Have 38v at post on solenoid and other post when pedal pressed. Any help greatly appreciated!

BGW

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JohnnieB

The potentiometer ought to go from about Zero Ohms with pedal up to about 5,000 Ohms with pedal down.

tmaxx2007

Sorry it was a little over 5k ohms at full throttle. Is the pot meter good?Thanks JohnnieB!

JohnnieB

That is within specs for the pot.

If the solenoid clicks when the pedal is pushed, the problem is in the high current circuit.

If the cart moves a bit, or tries to, the most likely suspects are the battery pack failing under load or the F/R switch.

What is the battery pack voltage when the cart tries to move?

The attached service manual is for a 48V (1996 and later) Shuttle 6, but ought to be the same except for voltage.

Attached Files

cargo shuttle, shuttle,electric,6,28318G01R.pdf (16.13 MB, 0 views)

tmaxx2007

I bypassed f/r switch. Still dont move. Pack voltage with cart trying to move is 37.86v. Is there anything else I could be missing? Thanks

JohnnieB

Did you just bypass the microswitch (MS2) or the high current contacts????


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Connect a voltmeter between the solenoid's B- and M- terminals.

Push pedal just far enough for solenoid to click.

You should read FULL pack voltage.

tmaxx2007

I turned the f/r switch to forward when I put the wires directly together. Will the micro switch still need to be bypassed? I will try B- to M- tomorrow. Thanks for all your help!

JohnnieB

The solenoid is clicking so the microswitch is doing its job and there is no need to bypass it.

scottyb

Controller output test would be good to do now.
Voltage between B- and M- as Johnnie said should be full pack voltage when the solenoid just clicks and the reading should decrease as the pedal is pressed down. If this tests okay look to the F&R or a cable problem.
Sounds like motor is trying to go so should be okay.

tmaxx2007

I tried the B- to M- test. I get full pack voltage as solenoid clicks, when continually pushing down pedal the voltage starts to drop then comes back to full voltage. Is this a faulty pot meter?