Solenoid wont activate. Please Help!!!

[tcascario]

I have a 99 ezgo dcs 48v with alltrax dcx 400. Was driving the cart one day when it stopped moving. Solenoid would no longer activate. Talked to Alltrax and they said pin 6 was not pulling solenoid to ground. Returned controller to alltrax under warranty and got a new one. This did not fix the problem. Returned again to Alltrax because test showed same problem. They returned again and now same problem continues. Rear tires will turn for a short time from pre charge resistor but solenoid will not activate. Thanks for your help.

[scottyb]

Are you sure they said pin 6? Not 7?
Try disconnecting the blue wire from the solenoid and run a temp wire from this solenoid terminal to the pack main (-). does the cart operate with the (-) jumper in place?

[tcascario]

Thats what they said. I performed the test with Alltrax on 3 different occasions with same results. The solenoid will activate when grounded directly to battery pack negative.

[scottyb]

Then ...... it sounds like a controller failure? Call em back.

[tcascario]

Ok I will give them a call again. They have already had the controller 3 times without any changes. Thanks

[dcascario]

Is there any other possibilities I can look at here? Alltrax insists the controller is good. Any thing else I can be looking for?

[JohnnieB]

Symptoms sounds like a bad pedal switch.

Check the voltage on Pin-5. Should be zero with pedal up and go to pack voltage when pedal is pushed. (That is what tells the controller to activate the solenoid.)

BTW, the controller activates the solenoid by putting B- on Pin-7. (See attached schematic)

[dcascario]

We checked and verified that in the past. I am seeing the change at pin 5, but no change at pin 7, which should be pack voltage at 7 until pin 5 gets pack voltage, then 7 should drop to zero and activate the solenoid. Is that correct?

[scottyb]

Originally Posted by dcascario

We checked and verified that in the past. I am seeing the change at pin 5, but no change at pin 7, which should be pack voltage at 7 until pin 5 gets pack voltage, then 7 should drop to zero and activate the solenoid. Is that correct?

pin 7 should provide pack (-) voltage to activate solenoid.
I think this is just another way of looking at their (+) reading disappearing? Which I never tested....

[JohnnieB]

Originally Posted by dcascario

We checked and verified that in the past. I am seeing the change at pin 5, but no change at pin 7, which should be pack voltage at 7 until pin 5 gets pack voltage, then 7 should drop to zero and activate the solenoid. Is that correct?

Pin-7 should be pack voltage when Pin-5 is zero volts and drop to zero volts when Pin-5 goes to pack voltage.

The pack voltage at Pin-7 is coming through the solenoid coil, telling us that the coil is good and the series circuit through the Reed switch, Run/Tow switch, F/R switch and Keyswitch is applying pack voltage to the other side of the solenoid coil.

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Does the LED on the controller flash four time and then turn to steady Green when Key is turned ON and a direction is selected on the F/R?

What is the voltage on Pins 6, 9 & 10? Should be FULL pack voltage.