Upgraded ezgo no go

[tsmith_co]

Alltrax SR48500, upgraded solenoid, wiring, FNR. 48v upgrade. Stock 36v series motor and still stock throttle mechanisms.

Worked fine for couple months. Ran into an issue with pre-charge failure on alltrax. If I held the peddle to just after solenoid climes for about 20 seconds, then it was fine. Problem went away.

Now, click but no go. NO pre-charge failure. Green light on the alltrax controller.

Where do I start checking?

Freshly charged (every night)
Solenoid clicks.
Dash Meter reads 51.3volts
My handheld meter says 50.8 on pack (cheap handheld)
50.8 batt side of solenoid (large terminals)
48.5 controller side of solenoid (large terminals)

Edit: never mind. Controller is giving pre-charge error code.

Not sure how to proceed

Resistor measures 461 ohm.
Sometimes I can get the cart to move if I press the pedal until just after it clicks and hold it for 30 seconds. The release and floor it. Rare now

[JohnnieB]

The pre-charge failure means the voltage between the controller's B- terminal and the controller's B+ terminal varies more than 5V from the voltage between the controller's B- terminal a the KSI terminal (Red push-on spade connector).

The KSI voltage comes from the reed switch, goes through MS-2 on F/R assembly,key switch and pedal switch, so there could be issues anywhere in those switches, wires and connections.

There is a 4-pin in-line connector at the end of the gray cable coming out of the pedal box that causes all sorts of problems. If you haven't already eliminated it, replace it with individual butt splices or solder joints and water proof them with marine grade (adhesive filled) shrink tubing.

[tsmith_co]

Thanks. I do still have that 4 pin connector. I’ll take a look at that and reply back

[tsmith_co]

Ok. Standing still -
B- and B+ on controller - 48.8v
Battery pack - 51.1v
KSI - 0v (obviously)

Press pedal -
B- and B+ - 41.1v (when cart wont move - precharge failure code)
B- and B+ - 51.1v (when cart will move)
KSI - 51v every time

So, the solenoid is bad?

[JohnnieB]

Originally Posted by tsmith_co

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So, the solenoid is bad?

Maybe.

Connect DVM's Black test lead to the solenoid's battery side large terminal and Red test lead to the solenoid's controller side large terminal.


Should go to Zero volts when solenoid closes.

If you red about 10V or so when you get the precharge failure, the solenoid is bad.