EZGO Express S4 48V No Solenoid Click

[Bill_Johnson]

This is my first post, so please be gentle. I am fairly technical and know which end of the volt meter has the pointy bits. :).

I have a fairly new Express S4 electric and recently replaced batteries with RowPow lithium. That went well and cart ran fine until I accidentally touched the key switch white/yellow wire to ground with the power on. (I know, I know).

After that cart would not go. I figured it was a fuse but after not finding any blown fuses, I replaced the old Curtis 1268? Controller with a new Navitas controller. (That installation went well)

But….and its a big ole butt….The cart still will not go.

Battery is full (52V).

With key switch on, press pedal…hear the click on the pedal micro switch but no click on solenoid. Cart does not move (of course). (Verified that the micro switch shorts its terminals when it clicks)

Verified that I have 48V on controller connector (J1) pins 1,2,3,4,5,6,7,8,10,11,and 12.

On the solenoid the small wires are yellow and blue and these always stay at 48V and never drop to zero. I verified that there is 48V on pin J1-17 (which I think should drop to 0 and trigger the solenoid.

So…I guess either the new controller is bad, or there is some other interlock that is telling the controller not to operate solenoid.

One more clue… The Navitas has a status LED that is blinking an error code (2-4)…This Says that the Controller is not “pre-charging”. Description: Abnormally low voltage on controller between B+ and B-.

Any ideas?

Cheers,
Bill

[kgsc]

On the Curtis j1-17 goes to ground when all the conditions are met to go. Don’t know much more about the Navitas

[Bill_Johnson]

It’s the same wiring harness… J1-17 not going to ground. I’m thinking that there is a condition that is not met but can’t figure out which one.

[Bill_Johnson]

One thing I forgot to add…

There is no pre-charge resistor nor diode on the solenoid. This is how it came from the factory as far as I can tell.

Bill

[Bill_Johnson]

Guys,

It seems to be better. Why it is better I have no clue. I am leaving this bread crumb for the next guy to find.

I was getting error message 2-4 which says something about a “pre-charging” issue. The manual points to faulty wiring…but the wiring is stock and in good shape. It then instructs to remove all the wires from the controller except the B- then test. If that clears the issue, add back the B+ And test. Then the M, ….

Once I did all this the controller clicked the relay as it is supposed to.

The only problem that was left was that the cart moved in the wrong direction. I swapped the F1 and F2 cables and now the cart moves like it is supposed to.

Hope this helps someone.

Bill