EZGO TXT 36V PDS Solenoid Won't Click

[dkaerche]

My batteries were starting to wear down but still functional. Replaced cables with 2 gauge cables, one at a time, including solenoid, controller and motor. Forgot to tighten the B-Battery cable, and when I went to test it got a spark from the loose connection. Tightened the connection, but the solenoid will not click. Diode gets super hot. Replaced solenoid, and no change. Starting running tests from the F section of the repair and service manual. Self tests gives a code 2-1. Started running the pinpoint tests. All good until step 9. Voltage between B- and controller side of solenoid with Key off, switch in neutral, and run-tow switch to run is only .2 volts (two-tenths). Per the diagnostic routine the the good reading should be between .4-.8 less than reference voltage (38.1), and the bad reading should be between 1-5 volts less than reference voltage, necessitating the controller replacement. However, I am only reading .2 volt. Not sure how to interpret this reading. Looking for some direction. Do I need to do a discharge test on the batteries? Just not sure where to go and do not want to keep throwing money at it.

[dkaerche]

I am sorry, resistor gets super hot. Not diode.

[kgsc]

Cart just sitting there should be just under pack voltage on the controller side of the solenoid. With pedal pushed it should go to full. Also with the pedal pushed and your leads on yellow and blue of the solenoid that should go to pack positive. If that happens and the above test fails then the solenoid is bad.

[dkaerche]

It isn't reading pack voltage. It is reading .2V on controller side of solenoid. Pack voltage is 38.1V I do not know how to interpret this.

[kgsc]

Does yellow and blue have pack voltage? If so solenoid is bad.

[dkaerche]

Thanks kgsc, I will check.

[dkaerche]

So I checked with key off, key on, direction switch on forward, neutral and reverse. I ran the test in all modes. Pack voltage wis 38.1. Voltage at controller side of solenoid is .2 volts. Putting the meter on the blue and yellow contacts of the solenoid read .2 volts. It never varies as the pedal is pushed down. No click heard. When I take a jumper from B- to control side of solenoid, I hear the solenoid click, so I am assuming solenoid is working. This has me stumped. Next step?

[kgsc]

If you get power with your positive lead on yellow and your negative lead on B- then the solenoid is getting the positive side of the circuit. The controller will send ground to blue when all the correct signals are received. Does the reverse buzzer work?

[dkaerche]

Yes, reverse buzzer works. I'll check the other part now.

[dkaerche]

With key on and in Forward position I get pack voltage, 39.1 with neg to B- and Pos to yellow on solenoid.