Controller and solenoid issues

John12g

I have a 03 EZ-GO. I just recently found out I have an upgraded controller after my kids were riding the cart and it failed to move. I talked with a local dealer and they informed me I needed to upgrade to larger wires, HD solenoid, and HD FNR switch. I purchased all three items new. I am showing pics of new items and one of old solenoid. So I put all new items back on cart and went to hook negative terminal back up and have arcing when I touch the terminal. I put all wires back in same place they came off of but the solenoid I might not be to sure of. The old one had side posts and the new one has top posts. I tried switching wires around just to be sure but still have arcing. I also had some of the smaller wires start smoking. I hope I have not messed anything else up but not sure what to do now. Hopefully you can help. Thanks in advance.
Old solenoid
New solenoid

Controller

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BGW

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radioman

I would suggest you take it to a local shop. Smoking wires are not a good sign. Replacing parts without some troubleshooting first to find where the problem is also not a good sign.

Golferdave

An arc can be normal but
smoking wires is not

Run/Tow switch in Tow?

Polarity of Diode &/or wires on solenoid small terminals might be wrong . That can cause smoke.

scottyb

The arc is normal for the first time when controller is not pre-charged.
No harm in that. No run/tow switch in series carts.

John12g

Thanks for the replies. I got the smoking problem corrected. Backwards wires. Yea its my first cart lol. Now that I have that solved the cart still won't move. Used meter to check readings and have good readings on everything but the inductive throttle sensor. According to some other forums I've read I believe it should get a reading when the pedal is pressed. Yes or no? Could this be the problem with the cart not moving? Thanks for the help so far.


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scottyb

Attached is the test for TXT & DCS series carts. No signal or a smoked pedal micro switch will make the cart not go. The solenoid should click when you try to go.

Attached Images

DCS ITS.jpg (225.4 KB, 0 views)

Brandeis_

I did the test on the throttle sensor it says to put the meter on D.C. Volts and put the positive on the white and negative on the battery pack negative right? It was reading 0.00 and wouldn't change when depressing pedal but I still don't have a solenoid click?

John12g

Ok so got the new ITS installed. I have a click on the solenoid but still no reading on the ITS and still no movement. Any other ideas before I bite the bullet and carry to a shop? Thanks in advance.


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Seaquell

In my opinion your parts dealer that sold you the parts should have the decency to walk you through everything.

After all he told you what to replace.
I do hope that someone can help you get it going

cgtech

Do your ITS voltage tests at the sensor itself, and do it at the controller plug too. If you get nothing anywhere, that would help ndicate the controller is not sending a source voltage to the sensor.