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Old 08-14-2020, 04:02 PM   #21
jeffro22
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Default Re: Solenoids failing -mzj-400

Added my diode and moved solenoid mounting position.

Does this look correct?
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Old 08-16-2020, 06:55 AM   #22
Sergio
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Default Re: Solenoids failing -mzj-400

The 10A10 behind the solenoid shows the "stripe" towards the battery cable so that is OK.

Hard to tell the wire colors on the small posts, but the stripe of the "fly-back" diode goes with the light blue positive activation wire.

The Solenoid mounting orientation is correct.
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Old 08-17-2020, 12:53 PM   #23
jeffro22
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Default Re: Solenoids failing -mzj-400

Quote:
Originally Posted by Sergio View Post
The 10A10 behind the solenoid shows the "stripe" towards the battery cable so that is OK.

Hard to tell the wire colors on the small posts, but the stripe of the "fly-back" diode goes with the light blue positive activation wire.

The Solenoid mounting orientation is correct.

Sergio, thank you for the help!

The small wires should be correct as I didn't change anything and the stripe is facing the light blue wire

hopefully the mounting position change will make a difference
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Old 08-31-2020, 10:44 AM   #24
gljohn0
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Default Re: Solenoids failing -mzj-400

I'm thinking I have a solenoid issue as well. Here's an interesting question: what happens if you do not use the big diode on the big posts? I have the XCT Controller as well.

To make a long story short, my 2014 CC Precedent has been acting up in the last few weeks--upgrades were done well over a year ago and seemed to work fine. Sporadically, the cart simply won't work, but then will run fine the next day. I do not hear any clicking when it's not running, so that lead me to the solenoid. When I looked at the solenoid (local shop installation), I did not see a big diode on the big posts. I presume that's problematic?
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Old 08-31-2020, 03:28 PM   #25
Sergio
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Default Re: Solenoids failing -mzj-400

The big diode referred to as "Regen Diode" is there just in case You ever loose power to the Solenoid during a Regen event.

I ran my own Precedent with XCT 500 for almost one year without it, and I use Regen brake a lot, so the chances of loosing Solenoid power accidentally is not huge, but it is good to have the diode installed.

The only reason I did not add my sooner is due to the hassle of removing the batteries to get to the Solenoid.

I have my mzj-400 installed horizontally and never had any issues with the bottom contacts getting stuck.
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Old 10-03-2020, 12:05 PM   #26
Volt_Ampere
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Default Re: Solenoids failing -mzj-400

I just had an interesting failure with one of these MZJ-400 solenoids: The end of the plunger that opens the contacts on the holding coil got mushroomed over and no longer opened the switch. The pull-in coil overheated and shorted. Very bad! This solenoid worked four years in my Lithium Yamaha cart. This failure was tricky to diagnose.
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Old 10-03-2020, 11:49 PM   #27
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Default Re: Solenoids failing -mzj-400

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Originally Posted by Volt_Ampere View Post
I just had an interesting failure with one of these MZJ-400 solenoids: The end of the plunger that opens the contacts on the holding coil got mushroomed over and no longer opened the switch. The pull-in coil overheated and shorted. Very bad! This solenoid worked four years in my Lithium Yamaha cart. This failure was tricky to diagnose.
That seems to be a pretty disappointing run life.

My WAG cycle calculation: 4 years x 365 day/year x 100 cycles per day = 146,000 cycles (with the WAG of 100 cycles per day which is probably high).

This does not happen to "Made in China"?

These so called economy solenoids get pretty expensive when they won't run 1 million cycles!
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Old 10-08-2020, 12:07 PM   #28
Volt_Ampere
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Default Re: Solenoids failing -mzj-400

Mine says Guizhou Tiany ELectrical Co on it. Does not have a country of manufacture. It was not a cheap knock off - I bought it from one of the respected site sponsors here. I agree that this should have lasted MUCH longer. The main contacts look brand new - no wear or marks on them at all. The end of the plunger was definitely the failure point.
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Old 10-08-2020, 02:46 PM   #29
scottyb
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Default Re: Solenoids failing -mzj-400

There are many companies manufacturing this MZJ400 type solenoid. The quality is not the same everywhere. This is one problem with this contactor. There are single and dual coil models also. I generally find the dual coil A models to be of higher quality.
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Old 10-08-2020, 02:59 PM   #30
Volt_Ampere
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Default Re: Solenoids failing -mzj-400

Problem with mine was caused by the dual coil switch not opening because the plunger tip mushroomed out and no longer opened the switch. The dual coil draws about 3 amps with the switch closed which is enough to smoke the coil. (3 amps at 48V is 150W)
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