94 club car quit running- again

[pitstop racing]

OK, just took one of the solenoids that quit apart....I have been a transformer engineer for 15 years, so I know a little about these things...the winding of the coil is open, the wires burnt. That would indicate too much current in the activation circuit. The plunger/contactor works freely, so it's not fused or anything from over current to the controller/motor. I am going to try to figure out a way to measure these currents...any ideas what would be normal?

[rabbitreborn]

Pitstop, I know you ordered another Solenoid. did you order a HD this time? It sounds as though somehow you are activating the solenoid with more current than the solenoid can handle (although how this is possible considering your total pack voltage, I have no idea). When you are charging, are you turning off the key and putting the car in neutral? I've never had this happen before that literally 3 solenoids blew in a matter of weeks. Possibly there is a way to ensure that ONLY 36 volts are going to the activation side of the solenoid, but I wouldn't know how to do that. If you have an old set of test leads for your multimeter, maybe cut off the ends and install small ring connects and attach them on a permanent basis to the activation coil on the solenoid to activly monitor the voltage going to it while running the cart?

[pitstop racing]

I am going to try several things this time...I did get a HD coil. I am also replacing the diode, resistor, and gas pedal microswitch just in case. I also picked up some low current fuses that I am going to insert on one side of the activation circuit to see what happens. Monitoring the voltage would be easy enough, so I can try that also.