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Old 09-29-2007, 11:45 PM   #1
indyaudioguy
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Default 1996 Electric Electrical Problem

Hi Cart guys!

My dad has a 1996, 36V Electric. It would not go, intermittent...I diagnosed an intermittent solenoid. I ordered a new one, but before I could install it, my Dad did it hmself. (bad idea!) He told me that it still did not work...but that the backup buzzer beeped a few times and then NOTHING worked. I looked at his installation, and he had installed the diode backwards across the coil of the solenoid.

This thing is deadsville. I have scoured this vehicle for fuses, and found none. I have dismantled the controller to look for a PCB mounted fuse and struck out there too. Did he damage the controller, or is there something else to consider?

Also, he routed the resistor too near the body of the solenoid and when I nudged it, it shorted and burned one leg off. What value (resistance and wattage is that resistor?)

Please help if you can.

Thank you!

Scott

scott@andersonelectronics.net
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Old 09-30-2007, 12:40 AM   #2
phasetim
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Default Re: 1996 Electric Electrical Problem

instead of it being an intermittent solenoid, it could have been the reed switch.. its a safety on the charger receptacle.... theres a small wire connected there, disconnect it, then on the wire running towards the controller attach a jumper to your main battery +, if it works the reed switch is toast, then you can either buy a new one, or hardwire that jumper cable...

if that doesn't do it, i would contact ez-gos tech support staff, and ask them to send you a diagnostic tree... or buy the book from a dealer..
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Old 09-30-2007, 12:46 AM   #3
indyaudioguy
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Default Re: 1996 Electric Electrical Problem

Thanks for the suggestion. This one was definitely the solenoid at first, though. The trouble was repeatable and could always be solved with a very slight tap on the solenoid body.

I wanted to know if the reversed diode could have damaged the controller, or I was hoping that someone could tell me how to test the controller. There is B+ voltage at the large controller terminal, but nothing on the control wiring coming off the controller.

I will give EZGO a call on Monday for sure, though.

Thanks again!
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Old 09-30-2007, 12:51 AM   #4
phasetim
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Default Re: 1996 Electric Electrical Problem

first question does your solenoid click?

if not, then you more than likely have a problem before the controller..

if so trace your voltage in to the controller.. positive and negative.... then follow it out of the controller... (easy to just say that, when you see about 20 a day lol)..
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Old 09-30-2007, 01:33 AM   #5
indyaudioguy
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Default Re: 1996 Electric Electrical Problem

The solenoid does not click since he did the replacement. He said that the back up buzzer beeped about 3 times and then quit when he reconnected the battery. That made me think that a control fuse may have opened somewhere because of the reversed diode, but I could not find a fuse in this cart anywhere.

If the problem lies before the controller...what should i check???

I am an electronic technician and an industrial electrician...but never worked on a cart before.

Thanks so much!

Scott
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Old 09-30-2007, 07:53 AM   #6
phasetim
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Default Re: 1996 Electric Electrical Problem

i would start by finding which side of your voltage is failing, or see if the solenoid you bought is bad...

jack a wheel up for safety... (almost killed myself skipping this step once)

take a multimeter set to d.c. and go to your activating posts on your solenoid (the small ones).... turn key switch on, put car in forward, and then activate pedal... if there is 36v (or near) on those post with no solenoid click, buy a new solenoid....

if you are not getting 36v, trace it backwards.... go from the negative activating post to battery pack +, and from positive activating post to battery pack -... (if you cant tell which one is which, just take a guess, and see (providing you have a digital multimeter)...

in any case, each side of the solenoid is activated by different items... one kill switch is the reed switch i already mentioned... and depending on the setup of your vehicle there is a couple others... check microswitches on your f/r assembly, they control activation... then also underneath your floor mat there is a pedal box, which has the ITS (inductive throttle sensor) and it has a microswitch that can fail..... (remember, when a system is not fused, the weakest link then becomes the fuse, blowing when it reaches too much stress) in the case of your dads car, the micros or a small control wire may have been fried...

I would seriously consider taking it to a trained technician if you have one locally, or one that is honest locally... I cant tell you how many times people have damaged their car further due to a small issue... the biggest oops Ive seen is a guy that changed his motor, controller, and batteries, all because a control wire was loose... .50 cent wire terminal cost him nearly $2500
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Old 09-30-2007, 09:46 AM   #7
indyaudioguy
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Default Re: 1996 Electric Electrical Problem

Thanks for the continued help! I want to keep fighting it myself for now...it is getting personal! If I get totally stuck, though, I guess I will load it up and take it somewhere.

I can tell you that the solenoid is good, as I can manually activate it. I have measured across it's coil, turned on the key and pressed the pedal and there is no change. I was not aware that BOTH sides require activation though. I assumed that the negative side was directly wired and that the positive side would be switched on and off. I will use your suggestion and try to follow it backwards from each side.

I wish that I had a wiring diagram, and still might order one from EZGO.

Thanks!

Scott
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Old 09-30-2007, 02:01 PM   #8
ruredy
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Default Re: 1996 Electric Electrical Problem

This thread may help some, it does have some diagrams and trouble shooting help.
http://www.buggiesgonewild.com/elect...your-ezgo.html
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Old 09-30-2007, 06:12 PM   #9
phasetim
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Default Re: 1996 Electric Electrical Problem

ez go will fax you a wiring diagram for free, they may fax you diagnostic trees for free as well.. (havent tried, I always have those)...
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Old 10-01-2007, 12:24 PM   #10
jclemmojoe
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Default Re: 1996 Electric Electrical Problem

Hey indyaudioguy!

I think I have what you need if you'll e-mail me a request.

I recently ordered a DVD service manual and it has all the trouble shooting trees and wiring schematic. I'll be glad to forward to you. Its on adobe 7.0 format so you can do about anything with it you choose.

Regards
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