2005 Club Car Stopped - Testing

Jano_64

OK. I have a 2005 Club Car Champion, 48V. Been running for a year with no issues. Then, a few days ago it just quit. Everything seems to be working. It will not go forward or back. Here is what I do know:

Batteries are good. Each one is above 12V and the pack is above 51V.

The solenoid does not make a noise. I did some testing on the solenoid. With the (+) wire landed on the coil, I can jumper the (-) coil terminal to battery (-) and the coil engergizes. Of course this is 48V, with the solenoid hooked up normal, I think it is only getting 26 to 28v. Voltage does not change with accelerator pressing. Here is the weird thing, I check continuity across the big terminals with the coil energized, they appear to not be closing. So I bypassed the solenoid by placing the two big wires on the same terminal...still nothing.

I did some resistance readings on the MCOR. They seem to be within range. I took voltage reading on the 3 pin connector going to the MCOR. White and purple wires are fine. Yellow wire had no voltage.


The F/R switch is working properly. The Run/Tow switch seems to be fine.

One thing I did notice, whenever I unhook the batteries and hook them back up, the reverse buzzer will not work. I have to connect the charger. After connection is made to the charger, the reverse buzzer starts working again.

The wheels turn freely. Any ideas?

BGW

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theboss20

How old are the batteries? Sounds like you have a battery that's not holding up under a load even though your voltage is good...there is a test for the batteries under load but it won't work if the cart won't run. If you could find a battery supplier with a battery load tester I would have the batteries load tested. It's been my experience that the battery closest to the main pos. cable tends to fail first.

jjance

Based on your statement about the reverse buzzer malfunction I'm thinking it might have something to do with the OBC. Try resetting the OBC. If that doesn't work try bypassing the OBC as described in this sticky.

http://www.buggiesgonewild.com/elect...excel-obc.html

Jano_64

I have tried resetting the OBC but didn't notice any difference afterwards. As for bypassing the OBC, I looked over the stick post referenced and am a little confused.

I have disconnected the black lead to the charging receptable from the OBC and connected it to pack (-). My solenoid coil (-) is a blue/white wire that goes to the controller not a yellow one. So I am not sure what to do next to finish the bypass.

Thanks in advance.

jjance

There is a six pin connector on the OBC. Unplug it and jumper the blue and white wires together with a paperclip on the female pin side. Then check to see if your cart runs. No need to change the big black wire.

Jano_64

I jumpered the blue and white wires on the female pin side. No change. Will not run in forward or reverse. Solenoid still does not engage. As I stated in my first post, even with the solenoid bypassed, it does not help.

The batteries are three years old. Could they keep the solenoid from engaging? Sounds like it may be the controller. Like I said before, when I put 48V to the solenoid it clicks, but hooked up normally, it is not getting the voltage. Is there a check or test to perform on the controller?

jjance

On the two big terminals of the solenoid there is also a small wire. Check to make sure it's connected to the side that goes to the battery.

Jano_64

Yes. The wiring and connections on the cart are in great condition. Although I'm unable to locate a 05 wiring diagram, the cart looks like the 2001-2004 diagram on the sticky in this section of the forums. It is unaltered and all appears original. I did check two fuses and they are fine.

Jano_64

OK. So I found the following guide: http://www.fsip.biz/Documents/Club%2...leshooting.pdf

I noticed that the green wire from the foot switch to the controller was not showing voltage. So to check I jumpered the green and blue at the foot switch plug, turned the key, hit the gas, and VIOLA! Solenoid engergized and wheels spinning. So the MCOR it is.

kantuckian

Good for testing mcor