Destroyed Solenoid?

jponder · 03-08-2011, 03:15 PM

Hey all, I have a huge problem. I recently converted to a 48 system on my ancient EZGO marathon and it wont budge. Here's the deal, I got a 48v 350A controller, 48v solenoid, 4ga wires, and 2 more 6v batteries. I connected everything the same way I took it off, except I didn't mark the direction of the diode on the solenoid. As I make the final connection to the ignition, I got a small spark and puff of smoke. I put in forward and depress the pedal and I get no click from the solenoid. I disconnected and reconnected every wire, nothing. Here are some pics of the solenoid and controller wiring. How does it look?

wizardket · 03-08-2011, 04:58 PM

It looks like the Diode is backwards. Are those lugs as close as they look on the controller?

jponder · 03-08-2011, 05:21 PM

I thought it could have been the diode. I flipped it around and I still got no click from the solenoid. Is it possible that I blew it that initial go? I did tests with the voltmeter and here's what I got.

B+ to B- : 48.7
B- to Sol #1: 49.1
B- to Sol #2: 48.7

Any other tests I should do? As far as the controller, the wires are coming off at different angles so that none touch.

wizardket · 03-08-2011, 05:49 PM

With the diode backward, you had a dead short. It could fry a wire or other part. What year and drive system (series, PDS, DTS)?

jponder · 03-08-2011, 06:15 PM

It's a 93 EZGO Marathon series cart. It was converted to solid state before i got it. I added 2 more 6v batteries into the rear well, but other than that no differences in wiring. Also, as I was testing the solenoid, I touched the two small terminals with the leads and got a violent reaction that blew the tip off the red lead.

Is there a way to make sure I didn't kill the solenoid?

wizardket · 03-08-2011, 06:17 PM

Did you remove the diode?

Also, was this a 48v solenoid?

jponder · 03-08-2011, 07:12 PM

I took the diode off and changed the direction. It was on when the leads touched. It is a 48v solenoid.

wizardket · 03-08-2011, 07:16 PM

I would disconnect all the leads and test that the solenoid works. Without the diode attached, I would test that it works with 48v across the small terminals.

jponder · 03-08-2011, 08:01 PM

Sorry I'm new to this, how do I test if its working with the leads off? I've tried looking through the forums and online for ways to test this thing and can't find anything other than the tests I mentioned above. Also, is there a way to bypass the solenoid to see if the cart will go or if any other components are damaged?

03-08-2011, 05:21 PM	#3
jponder Not Yet Wild Join Date: Feb 2011 Posts: 6	Re: Destroyed Solenoid? I thought it could have been the diode. I flipped it around and I still got no click from the solenoid. Is it possible that I blew it that initial go? I did tests with the voltmeter and here's what I got. B+ to B- : 48.7 B- to Sol #1: 49.1 B- to Sol #2: 48.7 Any other tests I should do? As far as the controller, the wires are coming off at different angles so that none touch.
jponder Not Yet Wild Join Date: Feb 2011 Posts: 6

03-08-2011, 05:49 PM	#4
wizardket Gone Wild Join Date: Jan 2011 Location: Camino, CA. Posts: 300	Re: Destroyed Solenoid? With the diode backward, you had a dead short. It could fry a wire or other part. What year and drive system (series, PDS, DTS)?

03-08-2011, 06:15 PM	#5
jponder Not Yet Wild Join Date: Feb 2011 Posts: 6	Re: Destroyed Solenoid? It's a 93 EZGO Marathon series cart. It was converted to solid state before i got it. I added 2 more 6v batteries into the rear well, but other than that no differences in wiring. Also, as I was testing the solenoid, I touched the two small terminals with the leads and got a violent reaction that blew the tip off the red lead. Is there a way to make sure I didn't kill the solenoid?
jponder Not Yet Wild Join Date: Feb 2011 Posts: 6

03-08-2011, 06:17 PM	#6
wizardket Gone Wild Join Date: Jan 2011 Location: Camino, CA. Posts: 300	Re: Destroyed Solenoid? Did you remove the diode? Also, was this a 48v solenoid?

03-08-2011, 07:12 PM	#7
jponder Not Yet Wild Join Date: Feb 2011 Posts: 6	Re: Destroyed Solenoid? I took the diode off and changed the direction. It was on when the leads touched. It is a 48v solenoid.
jponder Not Yet Wild Join Date: Feb 2011 Posts: 6

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03-08-2011, 04:58 PM	#2
wizardket Gone Wild Join Date: Jan 2011 Location: Camino, CA. Posts: 300	Re: Destroyed Solenoid? It looks like the Diode is backwards. Are those lugs as close as they look on the controller?

03-08-2011, 07:16 PM	#8
wizardket Gone Wild Join Date: Jan 2011 Location: Camino, CA. Posts: 300	Re: Destroyed Solenoid? I would disconnect all the leads and test that the solenoid works. Without the diode attached, I would test that it works with 48v across the small terminals.

03-08-2011, 08:01 PM	#9
jponder Not Yet Wild Join Date: Feb 2011 Posts: 6	Re: Destroyed Solenoid? Sorry I'm new to this, how do I test if its working with the leads off? I've tried looking through the forums and online for ways to test this thing and can't find anything other than the tests I mentioned above. Also, is there a way to bypass the solenoid to see if the cart will go or if any other components are damaged?
jponder Not Yet Wild Join Date: Feb 2011 Posts: 6

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