48v solenoid engagement issue.

[contactsports]

Hi all, hope you can provider some basic advice to troubleshoot and resolve this issue.

We have a 48V EZGO cart that was made by Cushman (Textron), or maybe vice-versa. It has an EZGO wiring harness.

It has a standard ignition switch with light, a lever for forward and
reverse and I believe a standard pedal system. From what I recall, the
pedal used to engage the solenoid, but that stopped working. If I
bypass all systems (reed switch appears to have been bypassed
previously) and engage the solenoid directly from the ignition switch,
the cart works and I can drive it.

The controller has B+, B-, M-, a row
of spade connectors labeled 1, 2 and 3, and a spade that goes direct to
the reverse horn. There is also a single red wire that comes out of a
harness that has an EZGO sticker on it. It is a female spade connectors
and I'm assuming this is what is supposed to engage the solenoid, but it
is not giving out any voltage, even when pedal depressed.

Based on the fact I can engage the solenoid with the ignition switch and
everything else works, is it safe to assume the lever micro switches and
pedal circuit are working correctly?

Appreciate any help, thanks!


Bill

[kgsc]

Well from what you have described you have a series cart. If wired similarly to a standard txt cart the activation circuit starts at the reed switch then to the FnR switch, then to the key switch, then the foot pedal switch, then to the solenoid. Sounds like your pedal switch has died or the wires to it. I attached the txt diagram

[contactsports]

Thanks for the info, will trace some wires and see what I find.

Also, I see the diode is missing across the solenoid engagement coil, what effect will that have and is it required? If so, what amp rating does it need to be?

Thanks.

[kgsc]

Diode is there to protect the circuit. 3amp should be good. Stripe on the positive side. As for chasing wires look for a harness going to the pedal box with 4 wires in it. White, black and 2 others. The two others are the pedal switch.

[contactsports]

You were spot on, pedal switch had failed, ordered a new one. Will install a 3A diode, thanks again!

Another quick question, on the 12V bus, there are 4 fuses, one goes to horn, the other to lights. Do you know what the red one does and the white/yellow?

[JohnnieB]

Have to identify which Cushman cart before we can come up with the accessory wiring diagram.


Post the model and year off the ID tag, or pictures of cart using the paperclip to attach to a post.

[kgsc]

Jb is correct but here is the one for a txt

[contactsports]

Cool, thanks.

It is a 2002 (no date on dataplate, was told) BellHop 7E, D403.

The 3rd circuit (red wire) was for the brakes. I'm guessing the 4th circuit is for a factory option that was not installed?

Question, how exactly does the diode protect the circuit in this configuration?

[contactsports]

Found this info on another forum about the diode, for anyone else interested:

"When you stop applying current to the coil, its magnetic field collapses and induces a reverse voltage in the circuit. This reverse voltage may be much higher than the original voltage applied to the coil, and could damage other parts of the circuit. So you want to safely dissipate the energy. A diode in parallel with the coil, and installed so that it won't conduct when the original voltage is applied to the coil, will conduct when the coil induces the reverse voltage spike. The diode will absorb the electrical energy and radiate it away as heat. Other snubber circuits could also be used."

[contactsports]

Originally Posted by kgsc

Jb is correct but here is the one for a txt

I guess no go on the cart specific wiring diagram?