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Old 11-07-2014, 12:30 AM   #1
JwgreDeux
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Default New controller and now solenoid won't activate

Old controller was bad so put in a new one. Wired everything up sure I was about to be back on the go and nothing. Solenoid not activating. Wondering if it is bad and if I caused my old controller to fail. Need this thing running, where do I start?
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Old 11-07-2014, 02:07 AM   #2
radioman
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Default Re: New controller and now solenoid won't activate

Wondering what your cart model is.
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Old 11-07-2014, 07:41 AM   #3
JwgreDeux
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Default Re: New controller and now solenoid won't activate

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Originally Posted by radioman View Post
Wondering what your cart model is.
It's late 90s txt series 36 volt.
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Old 11-07-2014, 07:49 AM   #4
JohnnieB
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Default Re: New controller and now solenoid won't activate

Solenoid activation circuit highlighted in red.

First place to check is the smaller of the three wires coming out of the charge receptacle.
Attached Images
File Type: jpg Wiring Diagram - Series with KSI traced.JPG (58.9 KB, 0 views)
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Old 11-07-2014, 12:55 PM   #5
JwgreDeux
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Default Re: New controller and now solenoid won't activate

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Originally Posted by JohnnieB View Post
Solenoid activation circuit highlighted in red.

First place to check is the smaller of the three wires coming out of the charge receptacle.
Reed switch has been removed and the small wire and all connections look good.
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Old 11-07-2014, 01:59 PM   #6
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Default Re: New controller and now solenoid won't activate

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Originally Posted by JwgreDeux View Post
Reed switch has been removed and the small wire and all connections look good.
Looks are deceiving.

Connect the negative test lead of your DVM to the battery pack's main negative terminal.

If you don't have a DVM, get one. An inexpensive one from an auto parst store will suffice.

Touch the positive test lead to the solenoid's small terminal with two red wires on it.

You should read battery pack voltage. If not, start measuring the input and output of the switches along the highlighted path on the schematic I posted.
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Old 11-07-2014, 04:39 PM   #7
JwgreDeux
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Default Re: New controller and now solenoid won't activate

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Originally Posted by JohnnieB View Post
Looks are deceiving.

Connect the negative test lead of your DVM to the battery pack's main negative terminal.

If you don't have a DVM, get one. An inexpensive one from an auto parst store will suffice.

Touch the positive test lead to the solenoid's small terminal with two red wires on it.

You should read battery pack voltage. If not, start measuring the input and output of the switches along the highlighted path on the schematic I posted.
No voltage at all. All micro switches are clicking.
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Old 11-07-2014, 06:45 PM   #8
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Default Re: New controller and now solenoid won't activate

Well, if you have a battery pack in the cart and the reed switch is in fact bypassed, you ought to at least have voltage on the red wire at MS-2.
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Old 11-07-2014, 07:21 PM   #9
JwgreDeux
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Default Re: New controller and now solenoid won't activate

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Originally Posted by JohnnieB View Post
Well, if you have a battery pack in the cart and the reed switch is in fact bypassed, you ought to at least have voltage on the red wire at MS-2.
When the positive probe is on the batter and the negative probe on the red wires on the solenoid I have full voltage power.
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Old 11-08-2014, 02:07 AM   #10
radioman
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Default Re: New controller and now solenoid won't activate

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.
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