solenoid/controller

epotts · 11-09-2012, 06:42 PM

Started up a hill in my 36v 96 ezgo when positive to solenoid melted along with another battery cable. Solenoid is gone! How do I tell if controller is damaged? Would a bad solenoid normally cause this much damage?

scottyb · 11-09-2012, 07:20 PM

Is it a stock solenoid and control?
Are there any modifications to the cart? Tires?

What other battery cable melted?
What year is your ezgo?
How about a pic of the cart and the damage?

A bad solenoid would not cause cables to melt.

Gonkulor · 11-10-2012, 04:17 AM

Answer ScottyBs questions. That really sucks your melting stuff. You have some bad stuff going on.

JohnnieB · 11-10-2012, 08:20 AM

Welcome to BGW!

Ironically, the melted battery cable(s) and solenoid might have protected the controller.

In any case, you will most likely have to replace the solenoid and high current cables before testing the controller to determine if it is still okay.

----------
The cables and solenoid contacts had excessive resistance, so they overheated when the controller allowed the motor to draw a lot of Amps.

In the future, check the temperature of cables and components occasionally.
They will be warm after a hard run, but shouldn't be hot. (In general terms, they should be cooler than the hot water that comes out of a kitchen faucet.)

If they are hot, they have excessive resistance and whatever is causing it needs to be corrected before they melt or start a fire.

epotts · 11-10-2012, 09:17 AM

scottyb, Don't know yr(ID plate gone), but I think it's about a 2000 TXT Series. It's lifted/w big tires (22"), stock controller and solenoid. The negative post on the front driver side also over heated,but did not melt. I have pics, will send.

scottyb · 11-10-2012, 09:31 AM

The 22" tires and off road driving make the stock motor draw more amperage than originally designed. Within reason this is not a problem for the motor, more amperage = more torque. The problem lies in the stock delivery system. It is engineered to deliver just enough amperage to play golf. That means 300yd trips on relatively flat terrain and rest. If you want the cart to more severe duty you have to increase the amperage delivery system.... not just part of it but the complete system = Controller, solenoid, cables, and F&R.

11-09-2012, 06:42 PM	#1
epotts Not Yet Wild Join Date: Nov 2012 Posts: 3	solenoid/controller Started up a hill in my 36v 96 ezgo when positive to solenoid melted along with another battery cable. Solenoid is gone! How do I tell if controller is damaged? Would a bad solenoid normally cause this much damage?
epotts Not Yet Wild Join Date: Nov 2012 Posts: 3

11-09-2012, 07:20 PM	#2
scottyb Happy Carting Join Date: Dec 2007 Location: Southern California Posts: 73,410	Re: solenoid/controller Is it a stock solenoid and control? Are there any modifications to the cart? Tires? What other battery cable melted? What year is your ezgo? How about a pic of the cart and the damage? A bad solenoid would not cause cables to melt.

11-10-2012, 04:17 AM	#3
Gonkulor Astronautilator Join Date: Sep 2011 Location: North Idaho Posts: 1,494	Re: solenoid/controller Answer ScottyBs questions. That really sucks your melting stuff. You have some bad stuff going on.

11-10-2012, 08:20 AM	#4
JohnnieB Techno-Nerd Join Date: Jun 2011 Location: West Virginia Posts: 19,654	Re: solenoid/controller Welcome to BGW! Ironically, the melted battery cable(s) and solenoid might have protected the controller. In any case, you will most likely have to replace the solenoid and high current cables before testing the controller to determine if it is still okay. ---------- The cables and solenoid contacts had excessive resistance, so they overheated when the controller allowed the motor to draw a lot of Amps. In the future, check the temperature of cables and components occasionally. They will be warm after a hard run, but shouldn't be hot. (In general terms, they should be cooler than the hot water that comes out of a kitchen faucet.) If they are hot, they have excessive resistance and whatever is causing it needs to be corrected before they melt or start a fire.

11-10-2012, 09:17 AM	#5
epotts Not Yet Wild Join Date: Nov 2012 Posts: 3	Re: solenoid/controller scottyb, Don't know yr(ID plate gone), but I think it's about a 2000 TXT Series. It's lifted/w big tires (22"), stock controller and solenoid. The negative post on the front driver side also over heated,but did not melt. I have pics, will send.
epotts Not Yet Wild Join Date: Nov 2012 Posts: 3

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11-10-2012, 09:31 AM	#6
scottyb Happy Carting Join Date: Dec 2007 Location: Southern California Posts: 73,410	Re: solenoid/controller The 22" tires and off road driving make the stock motor draw more amperage than originally designed. Within reason this is not a problem for the motor, more amperage = more torque. The problem lies in the stock delivery system. It is engineered to deliver just enough amperage to play golf. That means 300yd trips on relatively flat terrain and rest. If you want the cart to more severe duty you have to increase the amperage delivery system.... not just part of it but the complete system = Controller, solenoid, cables, and F&R.

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