Solenoid clicks, no go

sowilliams

I know there have been a lot of threads about this but I can't seem to find one that really helps me. The cart was running fine one day and the next I get on it and it won't move. I do hear the solenoid click. Thought it may be the in the pedal box because the cart was left out in heavy rain but no moisture in box. I think I am hearing a beep when I press the pedal but could just be a squeak from the pedal rod. Does the micro switch emit a beep at any time? Bottom line, could someone give me the steps to check voltages. I have checked all connections and everything is tight. This is the cart in my sig. Battery pack was at 50.5 volts.

BGW

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kgsc

You need to check and confirm that your solenoid is getting voltage when you press the pedal. Also the Alltrax should have a status indicator.. And I see you have the reversing contactor so you need to check that too..

mike777

check all your plastic/molex connectors, unplug spray contact cleaner, reconnect, unplug repeat a few times, worked for me, similar setup and problem, good luck

sowilliams

Got power at solenoid so I was trying to see if I had power to the motor. I appears I do but not sure I tested it correctly. But anyway I assumed motor was bad so I removed the cables and tested motor by itself with just 12 volt charger while still on cart. I can hear motor trying to turn the wheels but of course it didn't since it was on the ground and such little voltage. Any suggestions before I pull motor for second test?

radioman

Trying to assume what is wrong with a electric golf cart is a big mistake. Being left in the rain would not normally cause motor to act up. There are a lot of ways to determine what is the problem with a voltmeter and some patience before tearing everything apart. These forums are full of information. Scroll through them to get some ideas.

JohnnieB

Do not try to run motor out of the cart. It does not have a front bearing, so the armature rubs on the stator when it is not properly mounted.

Leave it attached to the differential and lift the rear wheels off ground. Your 12V charger might turn it, but it may take more voltage.

If the solenoid is clicking, the problem is in the high current circuit.
Connect your DVM between the B- and M- terminals on the controller.
Push pedal just far enough to make the solenoid click and you should read FULL battery pack voltage.
If it isn't there, go searching for it with the lead that was on the M- terminal.
When you find it, the problem is between where you found it and the M- terminal on controller.

If it is there, push pedal to floor. Voltage should drop to zero.
If not either ITS or controller is bad.

You have an Alltrax controller, so the voltage between the ITS throttle input wires to the controller should be 10V with pedal pushed just far enough to get the solenoid to click and 6V with pedal down.

Attached Images

Motor Test - Series.jpg (32.5 KB, 0 views)

sowilliams

Full pack voltage between m- and b- so good there but voltage never drops when petal is pushed. Haven't been able to check voltage on ITS wires to the controller because I thought I was being real cute mounting the controller above the motor but now can't get to wires from the pedal box. But.... Realized I am getting error lights on controller indicating High Throttle Over Range (2 green, 3 red). Plugged in programmer and reset with no change.

By the way, thanks for reminder on not testing motor out of cart. I had learned that the hard way but forgotten. I definitely have CRS.

radioman

Suspect leakage between the ITS sensor wires. Locate the connector and clean it best you can. The leakage might be caused by cart being left in the rain and adding to the normal ITS output. Might be, might not be. Unplug leads on ITS module and see if cart moves when pedal pressed and the solenoid clicks.

sowilliams

No movement with leads on ITS disconnected but I did notice a small burn mark on the inside of the ITS (don't know my terminology). Looks like the nut on the plunger may be hitting there.

radioman

Do you still get the High Throttle Overange code with the ITS disconnected when you press the pedal? I had a problem with voltage leakage between on the ITS sensor leads fool the controller into thinking it is seeing current from the ITS with the ITS disconnected. The leakage proved to be caused by a damp and corroded molex plug from the pedal box wires leaking current from the voltage from the controller that normally powers the ITS module. This was a most unusual problem that I fought over several months. It always acted up when cart was left in rain and would go back to working properly when it dried out a few days. That may not be the trouble you are having at all but I thought of this when you mentioned your cart had been left in the rain. Locate that plug and give it a good going over. The controller may be seeing too much voltage on the ITS output lead and keeping the motor from taking off when you press the pedal and running into or over something. The controller don't care if the voltage is from a ITS module or wiring leakage. JohnnieB gave you some good tips how to check out some things without tearing the cart apart.