48v EZGO won't move

[jbar]

2013 EZGO TXT 48v.

We replaced the batteries and after replacement, we get 48+ volts at output on each end, but the cart will not move. The batteries seem to be wired the right way.

We do get a full battery showing on the meter of the dash when the key is turned on. That is the only response we are getting with the key on. Not only the cart does not move, but none of the electrical system seems to be working. The lights turn on and the horn do not work. We believe we replaced all the wires exactly as they were taken out.

Since the problem started, we replaced the charging port, with the thermal connector and replaced the solenoid with no luck. There does not seem to be a problem when the charger is connected. So the new charging port seems to be working. The charger shows normal readings when plugged in. All though at a full charge, the batteries seem to be charging.

The only fuse I could find was a 7 amp fuse behind the convertor. That fuse tested fine. I could not find any other fuses.

I have included a picture of the wires. There were some aftermarket wires connected as you can see in the picture. The one red wire on the negative terminal looks like it was replaced in the past. It goes from red to then a black wire that runs into the plug on the convertor. Both are black going into the convertor, even though the other end is red at the battery.

Does anyone have any suggestions on why the cart will not move? Or please give some suggestions on something we can test?

Thanks in advance.

[kgsc]

That cart has a sonic weld in the harness in front of the controller cover that has been known to be a failure point.. It supplies power to most of the circuits. If you have a handheld it would be very helpful here to chase down your failure.

[jbar]

I do have a meter and I can test it.

By chance can you show me a picture of what I am looking for regarding the "sonic weld"? I see some pictures online of sonic welds, but I don't remember seeing that in the controller housing when I was looking for fuses. Maybe I just missed it.

[scottyb]

A sonic weld is just a hi-tech wire weld method. Hard to believe it would fail unless water intrusion caused corrosion to the failure point... it is definitely something that is going to fall apart.
The sonic weld would be buried / hidden in the wire harness. If I recall correctly it is in front of the solenoid under the floor but try to get confirmation that is correct before cutting into the harness.

[kgsc]

Vibration can also cause it to fail. Last one I saw was in the wire loom harness between the controller and the solenoid.

[jbar]

OK, I will look around tonight and see what I can find. I will try some testing from the solenoid to the controller and see if I am getting current through the harness. Thanks