Solenoid clicks but wont move --- ITS testing

[ncseadad]

Hey guys, hope everyone survived the winter..

I am working on a late 90's early 2000's ezgo.
The tag has been removed. Its a 36 volt. PDS with a 1206 controller. This controller only has three lugs. A while back I installed a new solenoid and F/R switch and was working great since last summer but just stopped the other day.

All wires are clean/Good.
Batteries are good...37.7
Solenoid clicks but will not move..
Solenoid clicks so controls are good...
High Volt wire test shows good (Pack)

ITS test...testing the solenoid, I have pack voltage on battery side but nothing on the controller side. (no diodes on solenoid). That is with the key/F/R switch on or off. When the solenoid click I have pack volts on both sides. Is that solenoid bad because it does show any volts until the pedal is pushed and solenoid clicks....

OK...continuing on with ITS testing...Everything else in the test is dead on until you get to where you are checking controller output. Connect (-) probe to M- terminal. Connect (+) probe to B+. The reading is 0 which it should be however when I press on the pedal it stays on 0 and does not climb to pack volts...

My question is would having 0 volts on controller side of the solenoid have anything to do with having 0 to pack on the controller output...

Which is bad...solenoid...controller...or both...

Thanks Bill

[scottyb]

Did you check the ITS like this?

[ncseadad]

Good Morning Sir....Yes, I tested just like that...I did the test you posted in the stickys for a PDS...and everything check except No volts on controller side of solenoid and No increase of voltage checking the controller output..

Bill

[JohnnieB]

Let's back up a little and positively identify which drive system your cart has.

You said it was either late 90's or 2000 and that it had a Curtis 1206 controller.
Unfortunately that could be any of the three drive systems EZGO had in that era.

A Curtis 1206 (No Suffix) is a Series drive. (Six pin plug on top)
A Curtis 1206SX is a DCS made in model years 1995 through 1999. (Ten pin plug on top)
A Curtis 1206MX is a PDS which came out in model year 2000. ( No plug on top - five plugs on front)

With any of them, if you have FULL battery pack voltage on the controller side large terminal while the solenoid is energized, the solenoid is probably good.

When the solenoid is de-energized, the voltage will be less than full pack voltage.

Have to know which drive system you have to troubleshoot further.

[ncseadad]

OK JohnnieB...Im old so please try not to confuse me...lol...
You want to know what kind of controller I have..

A Curtis 1206 (No Suffix) is a Series drive. (Six pin plug on top)
A Curtis 1206SX is a DCS made in model years 1995 through 1999. (Ten pin plug on top)
A Curtis 1206MX is a PDS which came out in model year 2000. ( No plug on top - five plugs on front)

OK..It has three lugs on top marked B+ B- M- A four wire (ROBW) white plug on TOP.
That tells me its a 1206 according to you..
Now the cart has PDS on the side...and owner said he thought it might be a 2002 cart..
Now that according to you is a 1206MX

Seeing how its 3 lug and 4 wire plug on top, I would say its a plain 1206

I used the ITS test for non DCS cart that you posted somewhere on here...

Checking out the controller output..

Connect the minus probe to M-......Connect positive probe to B+...It shows no voltage...when pressing down the pedal it does nothing...no show of volts..

and don't forget...0 volts on controller side of solenoid...

Thanks my friend...

[scottyb]

Any chance you can post a pic of the control?

[JohnnieB]

White nylon plug on top with four wires says it is a series controller.
ROBW are the colors from Left to Right when viewed from the front of the cart looking towards the back.
The pin numbers for those four wires are from Right to Left:
Pin-1 = White
Pin-2 = Black
Pin-3 = Orange
Pin-4 = Red


Sounds like someone has changed the body on the cart if it has a PDS label on it.
--------------
Raise rear wheels off ground and put on jack stands so the half ton cart doesn't take off unexpectedly and run over someone or something.

Measure the battery pack voltage. This is the reference voltage (Vref).

Connect you DVM negative test lead to the controller's B- terminal and the positive test lead to the N- terminal.

Push pedal just far enough to make solenoid click and you should read Vref.

If not, use the positive test lead to follow the cables highlighted on the attached schematic until you find the voltage.

[ncseadad]

OK JohnnieB I did the test you last sent.
negative probe to B-
Positive probe to M-

When solenoid clicks I have pack volts 37.7

FYI..the test I did prior was from the stickys and it read....EZGO Diagnostic testing for Ezgo Solid State speed Control Systems..

ScottyB...I have a pic on my cell but have no idea how to send it...don't know how to get it to my PC

Thanks guys...

[JohnnieB]

Good, you get pack voltage between B- and M- when solenoid clicks.

Slowly push pedal to floor and the voltage should smoothly decrease to near 0V.

If not, either the controller or throttle is bad.

The check the ITS (Throttle) use the procedure Scotty posted (it is for a DCS, but the voltages are the same.)

[scottyb]

Originally Posted by ncseadad

OK JohnnieB I did the test you last sent.
negative probe to B-
Positive probe to M-

When solenoid clicks I have pack volts 37.7

FYI..the test I did prior was from the stickys and it read....EZGO Diagnostic testing for Ezgo Solid State speed Control Systems..

ScottyB...I have a pic on my cell but have no idea how to send it...don't know how to get it to my PC

Thanks guys...

Unless you are carrying the last known flip phone ..... you should be able to email the pic to yourself & save it & upload it to your post