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Old 09-21-2017, 03:33 PM   #11
scottyb
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Default Re: 1994 DS solid state conversion

Do you have a standard rotary F&R lever or reversing contactor button?
What is the pack voltage now?
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Old 09-21-2017, 03:51 PM   #12
Bigbird295
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Default Re: 1994 DS solid state conversion

Carts Unlimited HD f&r switch. 36.7 volts
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Old 09-30-2017, 09:45 PM   #13
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Default Re: 1994 DS solid state conversion

Working on the cart again.
36.6v battery pack
36.6v at both the small Solenoid spade terminals when the switch is on, pedal is depressed and in gear.
36.6v on + lug of solenoid (top with fuse)
35.8v on - lug of solenoid (bottom)
pre charged resistor is in place
Solenoid is not clicking.
On the controller, black connector 36.6v when pedal is depressed, 36.6v on red connector when pedal is depressed.
I have never seen the Led stat light come on at all.

I need help @ this point, is the Solenoid bad?
Is the controller bad?

Thanks, all help is appreciated,
Bigbird
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Old 09-30-2017, 10:41 PM   #14
NoleFan4Ever
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Default Re: 1994 DS solid state conversion

Both the large post should have full pack voltage when the solenoid engages, that 35.8 is just from the precharge resistor. If it is not closing (clicking) and you do have the correct inputs on the 2 small posts of 36 volts, then jumper across the 2 large posts (wheels jacked off the ground) and then if it does work you will know your solenoid is faulty. And the light should come on when you jump across the solenoid and power is on the circuit.
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Old 10-01-2017, 07:56 AM   #15
scottyb
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Default Re: 1994 DS solid state conversion

Jumping or bypassing the solenoid will only tell you if the controller or motor works and then only if the controller LED is lighting up. Don't jump the solenoid it's an overrated test that tells very little. I see 2 problems.

You say both small solenoid terminals have 36v power when the pedal is depressed. Specifically one wire should be 36v+ and other 36v-. Is that what you are getting? The plus side signal originates from the pedal switch. This 36v+ activates the solenoid and powers the SR controller.

If you can verify the controller has 36v between B+ and B-. And 36v + at the J1 red...... the controller should have an LED light or it has failed?
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Old 10-01-2017, 08:55 AM   #16
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Default Re: 1994 DS solid state conversion

Thank you both so much for the advice. Today I'm not where the cart is. Tomorrow I will be checking these things and reply to this thread.
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Old 10-01-2017, 09:17 AM   #17
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Default Re: 1994 DS solid state conversion

And if you want to test just the solenoid, then I prefer to disconnect the pack. Use a DVM for Continuity and probe the two small posts. If it beeps then the energizing coil has passed that part of the test. Now apply 36v + & - to the 2 small posts and see it is clicks. If it did and it actually closed in, you should now have continuity across the 2 large posts. (I do remove the precharge resistor when doing this) If you do not have continuity across the 2 large posts, then the internals have failed or are stuck.
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Old 10-02-2017, 08:41 AM   #18
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Default Re: 1994 DS solid state conversion

Thanks again for the support.

Nolefan I did the test as you have outlined and there is continuity between both large solenoid studs.

ScottyB I check what you shared and I find 36.6 positive on BOTH positive and negative small spades of the solenoid.

Bigbird
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Old 10-02-2017, 09:22 AM   #19
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Default Re: 1994 DS solid state conversion

Quote:
Originally Posted by Bigbird295 View Post
Thanks again for the support.

Nolefan I did the test as you have outlined and there is continuity between both large solenoid studs.

ScottyB I check what you shared and I find 36.6 positive on BOTH positive and negative small spades of the solenoid.

Bigbird
This is the problem.
You have incorrect wiring. As I said one wire is (+) and the other should be negative (-). Check your wiring against the install diagram.
Can you post a picture (not a close up) of the solenoid showing the wire connections and a explanation of where each small wire goes to so I can see what you have done.
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Old 10-02-2017, 09:29 AM   #20
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Default Re: 1994 DS solid state conversion

Scottyb got it answered,
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