Stumped

[papabearsc]

Old series ezgo belongs to my father....just quit one day. He just brought it to me to figure out as he can't really work the DVM and do stuff at the same time. Anyway, I'm stumped.

Using the stickied diagnostics thread, I've checked the following:
Pack voltage - 37.4
Pack voltage is present at battery side of solenoid.
Key on battery voltage is present at controller side of solenoid 36.4V

So resistor and solenoid are good.

Now to connecting a jumper wire from BL+ (I assume this is B+) to post on solenoid with red wires. I did this and got an arc...

How do I proceed without damaging something?

[kgsc]

If the solenoid is activated there should be pack voltage on both large terminals. What you measured on the controller side of the solenoid was just a little lower than pack because of the resistor. With it in forward and pedal pushed do you have pack voltage across the two small terminals on the solenoid?

[papabearsc]

Originally Posted by kgsc

If the solenoid is activated there should be pack voltage on both large terminals. What you measured on the controller side of the solenoid was just a little lower than pack because of the resistor. With it in forward and pedal pushed do you have pack voltage across the two small terminals on the solenoid?

No. Small posts of solenoid show 0V when pedal depressed with key on in forward.

[kgsc]

Then you have an activation circuit issue. Look at the attached diagram to see the route. Starts at the charger port.

[papabearsc]

Originally Posted by kgsc

Then you have an activation circuit issue. Look at the attached diagram to see the route. Starts at the charger port.

Thanks for the diagram, but it's all a blur for me! I can't read that...is there a way to troubleshoot it spelled out somewhere for me to chase with a DVM?

I'm just a dumb ole country boy

[kgsc]

Okay I will give it a shot. Check blue wire on the micro switch on the fnr for pack voltage. If there find the molex connector on a grey cable coming from the pedal box, it should have white, black, green and red wires. If blue had power and the key is on the green wire should have pack voltage. If no you will need to pull the key switch plate and check to see if blue has power there. If yes check green there. If good there is a bad wire from the key switch to the pedal. If blue doesn’t have power but it did at the micro bad blue wire. Back to the molex plug. If green is hot red should have pack when the pedal is pushed. If no bad foot pedal switch. If it does it runs to the solenoid.

And I guess I should have asked. Can you not read the diagram or not understand it? If you can’t see it if you click on or press the picture it will enlarge.

[papabearsc]

Originally Posted by kgsc

Okay I will give it a shot. Check blue wire on the micro switch on the fnr for pack voltage. If there find the molex connector on a grey cable coming from the pedal box, it should have white, black, green and red wires. If blue had power and the key is on the green wire should have pack voltage. If no you will need to pull the key switch plate and check to see if blue has power there. If yes check green there. If good there is a bad wire from the key switch to the pedal. If blue doesn’t have power but it did at the micro bad blue wire. Back to the molex plug. If green is hot red should have pack when the pedal is pushed. If no bad foot pedal switch. If it does it runs to the solenoid.

And I guess I should have asked. Can you not read the diagram or not understand it? If you can’t see it if you click on or press the picture it will enlarge.

I can physically see it, yes. Tracing the circuit isn't easy...I do thank you for your time in explaining it. I have power in and out of key and do NOT have it at green wire on pedal end of Molex connector. I will dig further in between the two.

Thank you for the help

[papabearsc]

Just out of boredom I put in a good known working controller from another cart we had.

I have 4.5V at green wire in Molex plug.

If I press pedal, I have just a few millivolts at the red wire in the pedal end of the plug.

So I have a bad pedal assembly?

[kgsc]

Green wire is fed from the key switch. If key switch has power on green and that same green doesn’t have power at the molex you have a broken wire between the two.

[papabearsc]

New discovery...

I have pack voltage into and out of key switch ONLY when selector is in REVERSE. NO voltage in forward...

In reverse I have pack voltage from key all way to Molex connector. In forward I have nothing. Cart will not operate in reverse either though.

When I took the top off the pedal box, the microswitch in there is flopping around...the little arm is loose and doesn't feel like it's doing anything.