Dead Cart, Help Diagnose based on this...

[yurtle]

Originally Posted by gregaustex

Perfect thanks. Should be good to go soon!

I added some extra stuff above, to try and explain how the thing failed. Don't worry if you don't understand right away. Stick around here awhile, even after you are up and running, and you can't help but learn.

[yurtle]

Make sure you install the diode - the small component on the small terminals - the same way the old one was, with the band on the side with red wires. This solenoid doesn't care which way you hook up the coil wires or the contactor cables. The only thing that is polarized is the diode. The resistor doesn't care.

[gregaustex]

Progress of sorts.

Put the new relay in. Double checked the diode. Reused the resistor that goes along the bottom from my old one.

Now the cart runs, but gutless. Feels like half power or so?

Double checked and everything is tight and "right". Took a picture and was not really that complicated.

Ideas?

[yurtle]

Originally Posted by gregaustex

Progress of sorts.

Put the new relay in. Reused the resistor that goes along the bottom from my old one.

Now the cart runs, but gutless. Feels like half power or so?

Will re-check all the connections (I took a pic), but everything is tight and it wasn't very complicated so I think it will be "right".

Ideas?

I included the resistor. Did you check inside the bubble wrap "pocket"?

It's a solenoid, not relay.

Try removing the 1/2 speed orange wire from the FNR MS4 on the wiring diagram I gave you a link to earlier. Could be MS4 is stuck closed.

[yurtle]

Often on series carts, the four wire Molex connector that connects the throttle MS and ITS to the wiring harness sometimes (often?) gets corroded. Try unplugging, spraying contact cleaner, and plug, unplug, plug a few times. It's located between the controller/solenoid and the FNR. You more than likely "disturbed" it while installing your HD solenoid. If that helps, hurts, or changes how it behaves, cut the Molex off and solder or butt splice the four wire pairs and cover with a good quality adhesive heat shrink.

If that doesn't help, try this:

http://www.buggiesgonewild.com/elect...e-testing.html

[gregaustex]

Originally Posted by yurtle

Often on series carts, the four wire Molex connector that connects the throttle MS and ITS to the wiring harness sometimes (often?) gets corroded. Try unplugging, spraying contact cleaner, and plug, unplug, plug a few times. It's located between the controller/solenoid and the FNR. You more than likely "disturbed" it while installing your HD solenoid. If that helps, hurts, or changes how it behaves, cut the Molex off and solder or butt splice the four wire pairs and cover with a good quality adhesive heat shrink.

If that doesn't help, try this:

http://www.buggiesgonewild.com/elect...e-testing.html

Great suggestions, will try them.

Sorry meant to say solenoid.

I knew you had mentioned the resistor but I went through the packaging carefully and no luck. Just did it again. Do you think the resistance of this solenoid might be different than stock?

Will look at the hings you suggested.

[yurtle]

Originally Posted by gregaustex

Great suggestions, will try them.

Sorry meant to say solenoid.

I knew you had mentioned the resistor but I went through the packaging carefully and no luck. Just did it again. Do you think the resistance of this solenoid might be different than stock?

Will look at the hings you suggested.

You're resister is fine. 36 volts needs 250 ohms. You change it when you go to 42 or 48 volts.

[gregaustex]

Pulled the connector, cleaned it out, that did the trick!

I guess the universal rule of troubleshooting applies to golf carts as much as anything else. There are always 2 things.

Thanks for all the help. Time to change the oil in the diff now :-)

[yurtle]

Originally Posted by gregaustex

Pulled the connector, cleaned it out, that did the trick!

I guess the universal rule of troubleshooting applies to golf carts as much as anything else. There are always 2 things.

Thanks for all the help. Time to change the oil in the diff now :-)

So, bad solenoid and bad Molex. 2 for 2.

[gregaustex]

Your track record is perfect so far.

One last oddity I need to figure out (seeing as so far I haven't figured anything out yet myself :-)

Feels like it is running with normal power, good torque, what I am used to as I go up the hill by my house. Then suddenly there's a surge and more power yet. Then after a bit it goes away...it's subtle and I only notice it because it comes on while I've already got it floored, but definite.

I might not have cleaned out that connector enough? I haven't direct wired it yet.

BTW I'd like to have a word with the guy at EZ-GO who decided there needed to be two awkward to access bolts on the bottom of that controller cover now that I've had to take it on and off a few times.