EZGO TXT 36V PDS Solenoid Won't Click

[kgsc]

You need to go through all the steps to see what is going on. If all you did was flip it to run without doing anything else and you get continuity on the main lugs after something is definitely wrong.

[dkaerche]

Well, that is what happened. I'll finish the tests. Thanks.

[dkaerche]

Anyway flip it to tow, disconnect the main wire on the lug going to B+ on the controller and also remove the resistor. Check for continuity on the main lugs. If none. Leave the wires disconnected and flip it back to run. Push the go pedal and see if the solenoid clicks and possibly closes. If nothing check for pack voltage on yellow and blue wires. If no voltage check for voltage on yellow and B-. If voltage there run a jumper from blue to B- and see if the solenoid clicks. If so check for continuity on the main lugs.

No continuity in tow. Solenoid does not click in run UNLESS MI turn key on and put it in FWD. But pushing pedal with key off no click. With key off, no voltage between yellow and B-.

[kgsc]

So in run, key on in forward the solenoid closes with power on yellow and blue? What about when the pedal is pushed?

[dkaerche]

So, in RUN, Key on and FWD, I am no longer getting a solenoid click, even when I press the pedal. I read on the yellow and blue slightly less than pack voltage (pack is 39.1, I am reading 37-38.5). Pedal down has no impact.

[dkaerche]

Any other tests I should run? My gut feel is that when I replaced the wires with 2 guage, the controller cover was hard to put on and
I had to push pretty hard. Maybe something shorted out, or a wire pulled out of one of the connectors??? I tried new batteries, and a new solenoid, and nothing seems to work.

[dkaerche]

Should I check continuity on every single small wire?

[kgsc]

If you have power on yellow+ and blue- the solenoid should close and the main lug that goes to the controller should have pack voltage. If not the solenoid has failed. That said the solenoid shouldn’t get voltage on the small wires until the pedal is pushed unless the pedal switch has failed closed. If you put it back in diagnostic mode do you still get the same errors?

[dkaerche]

B- disconnected from the solenoid main lug. It is in run position. Key is on, selector is set to FWD, and voltage between blue and yellow terminals is 38.6 Pack voltage is 39.1 Pushing down the gas pedal does not impact the voltage. Ran the diagnostic code again, still getting 4 long beeps, followed by 2-1 and the 2-1 keeps repeating. Is this a pedal switch issue? Thank you.

[kgsc]

You can try checking the pedal switch again with the cart in tow. 2-1 is a low voltage alert so leave the resistor off and reconnect the B+ wire back on the solenoid and see if that goes away.