Help me please 2003 club car ds

aaronbittues

i have a 2003 clubcar ds series motor(plumquick bandit) the cart quit running over a month ago checked MCOR tested bad opened it up and found that it was completely wore out on the wipers got new one still no go after much internet snooping of this forum found a thread for testing controller controller also tested bad sent controller out to be rebuilt by flight systems and upgraded to 400 amp put that in today still no go solenoid clicks and I am getting pack voltage across solenoid I don't know what to check next at a loss any help is appreciated I am trying to get this thing running again for my daughter who just had open heart surgery as a get well present

BGW

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jakesnake27

Alright, we've got to get this thing going for your daughter.

Are you certain that you connected the new controller correctly? Does the reverse buzzer sound when you put it into reverse?

aaronbittues

I am positive the controller is wired correctly I marked each wire and used the wiring diagram off the sticky when I took it out and put it back in the reverse buzzer hasn't worked in years

jakesnake27

Hmmm, so the MCOR is brand new right? Is the controller brand new?

aaronbittues

Jake I am sure it is wired correctly I used the wiring diagram in the sticks and marked each wire when I took it out and put it back in the reverse buzzer hasn't worked in years

aaronbittues

Brand new MCOR and the controller just came back today from rebuild and upgrade could it possibly be the forward reverse lever

jakesnake27

It could very well be the FR switch, here's your diagram just for reference:

Sergio

You can try a few tests to make sure the controller has all the input signals it needs:

Set the meter to 200v DC.

Measure from controller pin #1 to B-, You should get +48v when solenoid clicks.

Set the meter to 20v DC.

Measure from controller pin #3 to B-, You should get from 0 to 5v as the Pedal is pressed.

To test controller output.

Set meter to 200v DC.

Measure from controller B+ to M-, You should get from 0-48v as Pedal is pressed.

Make sure cart rear wheel(s) are off the ground.

If the motor runs, don't let it run at high speed.

aaronbittues

Thanks jake I will trouble shoot the switch tomorrow after work thank you for your replies I will let you know what I find on the switch

aaronbittues

Thank you Sergio I will do that test also and let you know what I find