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Electric EZGO Electric EZ GO Marathon, Medalist, TXT and RXV.



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Unread 03-08-2011, 02:15 PM   #1
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Default Destroyed Solenoid?

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?
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Unread 03-08-2011, 03:58 PM   #2
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Default Re: Destroyed Solenoid?

It looks like the Diode is backwards. Are those lugs as close as they look on the controller?
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Unread 03-08-2011, 04:21 PM   #3
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Default 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.
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Unread 03-08-2011, 04:49 PM   #4
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Default 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)?
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Unread 03-08-2011, 05:15 PM   #5
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Default 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?
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Unread 03-08-2011, 05:17 PM   #6
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Default Re: Destroyed Solenoid?

Did you remove the diode?

Also, was this a 48v solenoid?
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Unread 03-08-2011, 06:12 PM   #7
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Default Re: Destroyed Solenoid?

I took the diode off and changed the direction. It was on when the leads touched. It is a 48v solenoid.
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Unread 03-08-2011, 06:16 PM   #8
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Default 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.
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Unread 03-08-2011, 07:01 PM   #9
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Default 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?
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