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Unread 10-06-2015, 08:32 PM   #1
Not Yet Wild
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Default 93 Club Car DS With Scottyb's Conversion Kit Help

Everything has been perfect on my 93 DS and exceeded my expectations up to this point but I now have a problem. My son pulled it up to the front yard and it just stopped in the driveway. I cycled the key switch several times and actuated the solenoid but came up with nothing. I tried it again the next day after a full charge and it moved. Later that afternoon it did not. So far this is what I have done:

- Verified one green flash on Alltrax 4855 controller.

- Verified 50.8 v at the key switch wire going into the controller.

- I pulled all the cables, cleaned and applied the protectant.

- Pulled the connectors off of the controller for the throttle to test for the 0-5k and put them back on. It worked briefly just in the driveway but it is INOP now.

- Tested what I believe is the 4 or 40ohm resistor on the back of the solenoid. Got 1.8Mohm one way and reversed the leads to get a reading of Infinite. The resistor was still connected to the solenoid at the time. Should I have removed it?

Motor is the stock 36v motor. I'm running the 48v kit with 8 6v batteries. Could it be the motor?

What Am I missing here? what is the purpose of the resistor and the diode on the solenoid? Everything is pointing to the controller but I just wanted to see if it was something simple such as that resistor or the diode on top of the solenoid. We are leaving for Georgia Friday at noon. It is the youth opening weekend for deer season and I am at a loss, we use it to run about 2 miles into our stands. I really don't want to walk that with a 10 year old! What should I do? Any and all help is more that appreciated.

Regards,

X
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Unread 10-06-2015, 09:46 PM   #2
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Default Re: 93 Club Car DS With Scottyb's Conversion Kit

This may not have anything to do with your problem, but I hope you reinstalled the cables BEFORE you applied protectant.

The other guys will help on the other things. Good luck
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Unread 10-06-2015, 10:16 PM   #3
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Default Re: 93 Club Car DS With Scottyb's Conversion Kit

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Originally Posted by mrgolf View Post
This may not have anything to do with your problem, but I hope you reinstalled the cables BEFORE you applied protectant.

The other guys will help on the other things. Good luck
Yes sir I did.
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Unread 10-06-2015, 11:04 PM   #4
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Default Re: 93 Club Car DS With Scottyb's Conversion Kit Help

The resistor goes on the solenoid big posts.

There is a diode on the solenoid small posts.

I am guessing you measured the small posts, and yes, you need to disconnect the diode to test it.

If the measurement was on the small posts, the solenoid appears to be bad.

Set your meter to DC volts and place the leads on the solenoid small posts.

You should get pack voltage when you press the accelerator.

If You do and the solenoid does not close, you need a new solenoid and diode.
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Unread 10-06-2015, 11:15 PM   #5
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Default Re: 93 Club Car DS With Scottyb's Conversion Kit Help

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Originally Posted by Sergio View Post
The resistor goes on the solenoid big posts.

There is a diode on the solenoid small posts.

I am guessing you measured the small posts, and yes, you need to disconnect the diode to test it.

If the measurement was on the small posts, the solenoid appears to be bad.

Set your meter to DC volts and place the leads on the solenoid small posts.

You should get pack voltage when you press the accelerator.

If You do and the solenoid does not close, you need a new solenoid and diode.
I measured only the resistor on the large posts still connected. I can hear the solenoid engaging/clicking. I'll try disconnecting the diode on one lug and test from there.

Thanks
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Unread 10-07-2015, 06:26 AM   #6
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Default Re: 93 Club Car DS With Scottyb's Conversion Kit Help

Just be careful disconnecting or measuring things with power still applied, sometimes you can accidentally cause more trouble by shorting something.

Since the solenoid is clicking, just make sure it is actually closing the circuit before checking the rest of the high current system.

Lift one of the rear wheels off the ground.

Set your meter to DC voltage and place the leads on the solenoid big posts, you should read a few volts caused by the controller capacitors maintenance current.

Press the pedal and once the solenoid engages, that voltage should go to 0v if the contacts closed.

If that is working, measure the voltage between M- (positive meter probe) and B- (negative meter probe), the voltage range should be 48v (pedal up) to 0v (pedal down).

If the voltage range is good, check the FNR switch.
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Unread 10-07-2015, 07:00 AM   #7
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Default Re: 93 Club Car DS With Scottyb's Conversion Kit Help

Quote:
Originally Posted by Sergio View Post
Just be careful disconnecting or measuring things with power still applied, sometimes you can accidentally cause more trouble by shorting something.

Since the solenoid is clicking, just make sure it is actually closing the circuit before checking the rest of the high current system.

Lift one of the rear wheels off the ground.

Set your meter to DC voltage and place the leads on the solenoid big posts, you should read a few volts caused by the controller capacitors maintenance current.

Press the pedal and once the solenoid engages, that voltage should go to 0v if the contacts closed.

If that is working, measure the voltage between M- (positive meter probe) and B- (negative meter probe), the voltage range should be 48v (pedal up) to 0v (pedal down).

If the voltage range is good, check the FNR switch.
Roger that. Going to take the kids to school and I'm coming back to try that. Thank You.
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Unread 10-07-2015, 09:56 AM   #8
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Default Re: 93 Club Car DS With Scottyb's Conversion Kit Help

Quote:
Originally Posted by Sergio View Post
Just be careful disconnecting or measuring things with power still applied, sometimes you can accidentally cause more trouble by shorting something.

Since the solenoid is clicking, just make sure it is actually closing the circuit before checking the rest of the high current system.

Lift one of the rear wheels off the ground.

Set your meter to DC voltage and place the leads on the solenoid big posts, you should read a few volts caused by the controller capacitors maintenance current.

Press the pedal and once the solenoid engages, that voltage should go to 0v if the contacts closed.

If that is working, measure the voltage between M- (positive meter probe) and B- (negative meter probe), the voltage range should be 48v (pedal up) to 0v (pedal down).

If the voltage range is good, check the FNR switch.
Just checked all the items you listed 4.7v on the solenoid open and closed 0v. M- to B-, pack voltage down to zero as throttle pushed. I rang out the contacts on the F-N-R switch and all went well. Funny this is I just jacked it up and put it on jack stands. I tried the throttle for giggles and it worked. The only change from last night to this morning is it has a higher pack voltage due to me charging it when I took the kids to school. Go figure!

What am I missing?
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Unread 10-07-2015, 10:06 AM   #9
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Default Re: 93 Club Car DS With Scottyb's Conversion Kit Help

The pack voltage is not the problem since You had 50.8v before.

I would guess either the solenoid contacts were not closing, or there was a bad connection at the FNR.

Intermittent problems are hard to troubleshoot unless the issue exists at the time of the tests.

Take the voltmeter with You and a wrench in case the issue is the solenoid, You can temporarily wire the 2 cables on the solenoid big posts to a single post to get you out of the woods.
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Unread 10-07-2015, 10:15 AM   #10
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Default Re: 93 Club Car DS With Scottyb's Conversion Kit Help

Quote:
Originally Posted by Sergio View Post
The pack voltage is not the problem since You had 50.8v before.

I would guess either the solenoid contacts were not closing, or there was a bad connection at the FNR.

Intermittent problems are hard to troubleshoot unless the issue exists at the time of the tests.

Take the voltmeter with You and a wrench in case the issue is the solenoid, You can temporarily wire the 2 cables on the solenoid big posts to a single post to get you out of the woods.
The contacts do move somewhat inside the wiper for the F-N-R switch but I think that's normal. Its the heavy duty one that Scotty sells. I've been hearing the solenoid closing and opening all along. It sounds strong but do you think it could be the problem? Is there a test to rule out the controller? Would the higher voltage effect the controller and fool it into cooperating? For the heck of it, I'm going to run it down to 50.8 that I had last night to see if I can duplicate the problem. Thank you for your help on this.

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