changed solenoid , cart no go

[skindaddy]

1996 series cart
well i started out right!! i installed a new solenoid 200 amp and after i was done i turned key on reverse buzzer was going cause in rev. and touched the pedal and made a little snap like sound like a fuse blowing and i thought i seen a flash but the weird thing is the flash came from the driver side at least thats what i thought but nothnig is over there? anyway now buzzer dont work and cart wont move .

a couple things we just did this on my brothers same year and the little screws on the solenoid on his had one black and one red 18ga. wire combined on each terminal
and i think he had 4 big blade terminals on the controller

and on mine "the old solenoid" i had 2 blacks 1 red on a terminal ,-and 1 red on the other terminal , and on the controller i have only three big terminals m-, b+, and b-

i had hooked mine up like my brothers for some reason and dont know if this is where probs started , plus the diode thingy between the 2 little terminals

also anyone have wiring diagram for the series didnt see it in resources

 

[HotRodCarts]

The red wires should be on one small terminal and the black wires on the other. The stripe on the diode should aim at the red wires. If the solenoid is wired wrong and the diode was backward it will blow the reed switch in the charger receptacle which will cause the reverse buzzer to stop working. It may have also blown the micro switch inside the ITS box under the floor mat on the drivers side of the cart. After you get the wiring right on the solenoid you can jump the reed switch by unplugging it and running a jumper from the reed switch spade terminal to battery pack main positive (same battery terminal the white wire is connected to from the charger receptacle). Once you do that if the reverse buzzer starts working but the cart won't move you'll need to check the micro switch in the ITS box. Don't jump the reed switch until your positive you have the solenoid wiring right.

 

[skindaddy]

thanks ill try that. after i posted this i found the testing reed switch picture procedure so i'm with you on that, but if the switch is blown after testing is there a way to fix it? or replace?

 

[skindaddy]

also in the controller solenoid pic, there is a small wire looking at your pic on the right hooked to the 5/16" terminal on the solenoid whats that going to i only had 1 #6ga wire going to each plus the resistor that's it ??

 

[HotRodCarts]

You can get the reed switch at a EZGO dealer or online at places like BuggiesUnlimited. Take the charger receptacle cover off and you'll see it, it's very easy to replace. Or you can leave the reed switch bypassed if you want. All it really does is prevents the cart from running while the charger is plugged in. There's 36 volts going through the reed switch so make sure you unhook the main battery cables before replacing it.

You should have to small black wires on one small solenoid post, one going to the controller and one to the reverse buzzer. And two small red wires on the other small solenoid post, one going to the controller and the other going to the micro switch mounted inside the ITS box under the floor mat...

 

[skindaddy]

ok i work on it tonight, but i meant the big studs on the solenoid in your first pic you posted there looks like a little wire there but after i work on it ill be able to tell you more on what i got in the cart!

 

[skindaddy]

well i jumped the reed switch, which had what loooked like broke glass under the wires, anyway its works NOW, first i jumped it wrong and nothing, but then fixed my dumb mistake and now it works, ill guess i will just leave it jumped and save $55 , luckily micro switch works too!
man you saved my butt again

this site is great!

 

[HotRodCarts]

No problem! Glad you git it running...