New controller and now solenoid won't activate

[JohnnieB]

Originally Posted by JwgreDeux

When the positive probe is on the batter and the negative probe on the red wires on the solenoid I have full voltage power.

One may use Positive=True logic (Negative test lead on B-) or Negative=True logic (Positive test lead on B+) for troubleshooting DC circuits and arrive at the same conclusion.

That being: There is an open between the solenoid coil and the battery pack.

[JwgreDeux]

Originally Posted by radioman

You have an open circuit between battery plus and the solenoid red wires. Do as JohnnieB suggested. Put the negative voltmeter lead on battery negative and check the points highlighted in red on the drawing JohnnieB sent you for voltage. You should have voltage on the small wire from the charger receptacle reed switch wire if it is working or has been properly bypassed, both terminals of micro switch MS2 on the forward reverse switch (in forward), voltage on the key switch (key switch on) and voltage through the pedal micro switch MS3 when the pedal is depressed. There is trouble at one of these points or an open wire. This should be an easy problem to locate if you follow suggestions.

Traced through the fnr switch and it is good. How do I a was the key switch and pedal box?

[JwgreDeux]

Ok I have the pedal box open. There is 3 volts on the green wire in and zero on the red wire out when pedal is not pushed and zero when pedal is pushed.

[JwgreDeux]

Key is in on position. When key switched off, I get zero on the green wire.

[JwgreDeux]

Pedal micro is clicking and looks to be functioning.

[JohnnieB]

Originally Posted by JwgreDeux

Ok I have the pedal box open. There is 3 volts on the green wire in and zero on the red wire out when pedal is not pushed and zero when pedal is pushed.

There should be full battery pack voltage on the green wire.

What is the voltage on the red wire on MS-2? (MS-2 is located on F/R assembly)

If it is pack voltage, check voltage on the blue wire on MS-2.

If it is pack voltage, check voltage in and out of key switch. (Panel has the be removed)

[scottyb]

Thank you Johnny
We are all the way back to the beginning. Here is the solenoid activation diagram for Ezgo Series carts again.
You must have 36v (+) positive [read with black test lead on battery main (-)]
at all points of the red lines. Start at the beginning (source) before you pull the dash apart. Sometimes a simple origin problem is the fix.

[JwgreDeux]

Originally Posted by JohnnieB

There should be full battery pack voltage on the green wire.

What is the voltage on the red wire on MS-2? (MS-2 is located on F/R assembly)

If it is pack voltage, check voltage on the blue wire on MS-2.

If it is pack voltage, check voltage in and out of key switch. (Panel has the be removed)

Full pack voltage at the wires on the red and blue when in forward at the fnr, and on the orange at the fnr when in reverse.

Haven't opened dash up yet to check key switch. The voltage in to the pedal box actually fluctuates from 3 up to 8 volts when key is switched on and is zero when switched off. I will open it up tonight, what size rivet do I need to close it back?

[scottyb]

Do not remove the keyswitch panel unless you verify you have 36v going to it first?

See the OEM blue wire at the F&R micro-switch. It should have power in F and R . Does it?

[JohnnieB]

Originally Posted by JwgreDeux

Full pack voltage at the wires on the red and blue when in forward at the fnr, and on the orange at the fnr when in reverse.

Haven't opened dash up yet to check key switch. The voltage in to the pedal box actually fluctuates from 3 up to 8 volts when key is switched on and is zero when switched off. I will open it up tonight, what size rivet do I need to close it back?

Good. Now we know you have pack voltage on the blue wire going to the keyswitch, but not on the green wire going to the pedal switch. That narrows the problem down to the keyswitch, or the wires to and from it.

Push the tiny center pin in the rivet head, through the head and the rivet can be pulled out.



I replaced the rivets in mine with screws. Don't know what size, they were just a couple I had in a junk drawer.