2001 ezgo 36v no solenoid click

[Jkirby891]

Ok so I am needing a little help diagnosing this cart A customer told me it would only click but not move. When I arrived to pick the cart up he then told me his son tried replacing the solenoid when he hit the pedal they saw a little smoke come from solenoid and the new one wont even click. When I got there none of the main cables or charging receptacle was hooked up and all solenoid connections were loose.


I started by wiring everything back. I now have cart charging to full capacity as each battery was reading 6.2v. They are fairly new Trojans.

I tried jumping solenoid from b+ to red wires on small post of solenoid however when I do it arcs as if its a ground connecting to a positive.

Please help as I do not know where I should start looking nor do I see anything that could be causing that issue.

[ARKSoft84]

Have you done this yet?

Testing of the EZGO ELECTRONIC SPEED CONTROL - SERIES & PDS (NON DCS)
ALWAYS DISCONNECT THE NEGATIVE BATTERY CABLE BEFORE REMOVING CONTROLLER COVER. RE-CONNECT CABLE AFTER COVER IS REMOVED.
These test are to be conducted after making sure all wires and connections are clean and tight.
PLACE THE REAR OF THE CART SECURELY ON BLOCKS OR JACK STANDS FOR SAFETY
Connect (-) probe of meter on Battery Pack Negative (-) post. (This probe will on the post for the rest of the testing procedures) Connect (+) probe to the Battery Pack Positive (+) battery post. (This reading is the Battery Voltage and the amount of POWER TO THE CONTROLLER -
NOW, Key switch ON, gear selector in FORWARD, Place the (+) probe on the battery side of the solenoid's large post (If the reading is below battery voltage, check all wiring and terminals).
Place the (+) probe to the controller side of the solenoid's large post. The reading should be 0.1 to 3 volts less than battery voltage. If the reading is more than 3 volts less the battery voltage, the resistor is faulty. If the voltage is the same as the battery voltage, replace the solenoid.

[Jkirby891]

I will check this now.

I wanted to update I just pulled ignition the main blue feed wire only has 12.8 volts and does not power out to any other terminal except the lights. The ignition has 4 posts, the main one feeding power then 3 more one is for the lights and I'm sure one is the feed to the pedal switch that one is not getting power. IM not sure what the 4th wire is for. Also the battery gauge is not working and it is wired into the key switch.

[Jkirby891]

Pack voltage 38.5 volts

38.4 volts at B+ feeding into controller and on large post of solenoid feeding from controller. When I jump over to large post that feeds solenoid to battery pack I get 38.5 volts.

When key is ON nothing changes. I get no voltage on either small terminal. Whether the key is on or off.

[ARKSoft84]

Is this a Series cart, or a PDS cart?

[Jkirby891]

Originally Posted by ARKSoft84

Is this a Series cart, or a PDS cart?

It is a series. fnr lever at the feet. No run/tow switch.

[Jkirby891]

From what I have found thus far the ignition on these 4 terminal ezgo ignitions have both a 12v feed and a 36v feet or (pack voltage). My ignition is not getting a 36v feed it has only the 12v feed working. If anyone can suggest where to look it would be greatly appreciated.

[Jkirby891]

UPDATE

After further inspection I traced the 36v feed to ignition back to the forward micro switch. It had 38.6 v on red wire but 0 on blue wire when switch was activated. I removed both wires then connected with a jumper and now have 38.6 feed at ignition. When I turned ignition over to make sure I get 36v switch on and I had a small spark so I am going to replace that micro switch before going forward. I hope this fixes the issue however I feel as if there may be another issue. Until I fix this problem I cannot diagnose further.

[Jkirby891]

So today I have changed the micro switch and now have a 36v feed at ignition. Now here is the problem the small red wire that comes of the charging receptacle is what supplies power to the switches. Once the ignition is flipped on the small red wire starts smoking and the red casing started to appear so hot its melting. Can anyone tell me what might be going on?

[Jkirby891]

Put new red wire on charging receptacle and now when key gets turned on the two red wires on small post of solenoid are smoking.