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Old 03-14-2018, 05:38 PM   #1
acrosteve
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Default Trouble with DS drive system.

I am early in my troubleshooting, but did verify that the motor and drivetrian are functional as per standard DC motor testing procedure. However, the cart would not move when I got it. Just the solenoid click.

My cart is a 2002 DS with 6x8v batteries. Series, not a regen.

I am referencing this schematic - Sorry for the link to a different site, but that version has much clearer text than the one that is linked here.
Well, links are not allowed for new members - 950348vuv0.jpg



Anyway, my immediate question concerns the motor terminals - my motor has S1 and A1 next to each other, and S2 and A2 likewise. However, the schematics I have seen have S1 next to A2 and S2 next to A1. The motor was wired per the wire color to the terminal numbers, but those did not match the way the motor is physically laid out in the schematic.

Background is that the initial problem was the directional controller had been hot and melted somewhat. Also, one of the field terminals on the motor showed signs of high temperatures, but does not appear to have shorted out.
The motor is now replaced with new, as is the directional controller AND the motor controller.


More to come, but a quick answer on the terminals would be great if anyone knows.

Thanks
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Old 03-14-2018, 06:05 PM   #2
Mooncarter
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Default Re: Trouble with DS drive system.



Depending on the year of the cart the lugs may be situated differently. Some of the older ones are in a "row" newer ones not so. Either way your motor should be marked S1-A1-etc. either by a label or embossed in the housing.
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Old 03-14-2018, 07:04 PM   #3
mrgolf
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Default Re: Trouble with DS drive system.

Would club car and ezgo motors be marked different
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Old 03-14-2018, 08:33 PM   #4
acrosteve
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Default Re: Trouble with DS drive system.

Yea, motor is clearly labeled - Red Hawk Admiral. I will go with the motor labels. Really, changing them would only effect the direction of travel, and at this point, I am just hoping to get it moving under it's own power.

The small diode on the Solenoid is burnt up. That shouldn't effect anything should it? The resistor is ok, and it pulls in just fine.

I have not tracked it down yet, but the wire that energizes the solenoid is red. The diagram also shows a white/black one on the same terminal - the other end goes to SW1. That wire is unaccounted for so far. And there is only one red wire under the main + cable terminal. The diagram shows two red's and a green along with the large red one.

Is there an explanation of the limit switches on the forward/reverse switch? I know SW2 runs the reverse buzzer. SW1 is only closed in forward- but has the white/black wire previously mentioned. SW3 seems to indicate a neutral switch position. But then all 3 are closed in reverse.

Then, is there a breakdown or troubleshooting method for the throttle potentiometer?
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Old 03-14-2018, 09:46 PM   #5
Mooncarter
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Default Re: Trouble with DS drive system.

Look in the "stickies" and get the diagram for your cart wiring. That will explain it all.
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Old 03-15-2018, 05:26 AM   #6
acrosteve
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Default Re: Trouble with DS drive system.

Quote:
Originally Posted by Mooncarter View Post
Look in the "stickies" and get the diagram for your cart wiring. That will explain it all.
Thanks, but not really - I did read that thread, which is where I found the closest match diagram.

However, there are wires shown in the diagram that are at least partially "missing" on my cart. The harnesses all look to be in original condition.

I will trace the wires out more tonight, but at least one end of 3 or 4 wires do not go where the schematic shows.
For example - the white/black wire on the solenoid. It is present at the microswitch, but not at the solenoid.


Also, while I can trace the wires to the switches, I just wondered if there was a verbal explanation of each their purpose. They are wired right, but the cart won't run so I am looking at understanding why.


Also, what is the purpose of the resistor on the high amp terminals of the solenoid? Can I remove it for troubleshooting? I wonder sometimes if the contacts on my solenoid are making consistent contact. With the resistor there, you can't tell with a light or meter.

Thanks
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Old 03-15-2018, 03:53 PM   #7
acrosteve
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Default Re: Trouble with DS drive system.

Well, the "missing" wires have been found - they terminate in factory splices in the middle of the wires.


My cart will not run when I bypassed the OBC by unplugging it and jumping the yellow solenoid to the batt -.

On to checking the controller, which was already replaced with a reman, I believe. I do have the old one also.
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Old 03-15-2018, 04:04 PM   #8
acrosteve
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Default Re: Trouble with DS drive system.

I may have found something - -

When checking the controller, I do have 48v on terminal 1 when I depressed the throttle.

However, on the wires for terminals 2 & 3, I have 7.8K at 0 throttle, and decreasing to 2.2K at fully depressed.

Unless I am mistaken, the potentiometer should give 5K ohms at very low throttle, decreasing to 0 ohms at full throttle.

Can I temporary in a 5k pot to those terminals and use it in conjunction with the throttle pedal to test?

Thanks
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Old 03-15-2018, 04:16 PM   #9
Sergio
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Default Re: Trouble with DS drive system.

You need to account for all of those wires otherwise it is not "wired right".

Switch #1 closes in Forward and Reverse.
This switch completes the +48v positive from the Pedal micro-switch to the Solenoid coil positive activation (black/white wire).

Switch #2 only closes in Reverse.
This switch completes the Reverse buzzer negative circuit when the FNR is in Reverse.

Switch #3 is the "reduced speed" reverse.
This switch adds a 5.1kΩ resistor in series with the top of the throttle (green wire from controller) when the FNR is on Reverse which causes the maximum thtrolle to be about 1/2.

Trace the Solenoid positive activation wire to see where You are loosing the connection:
Solenoid Big Post -> Green wire -> Key Switch -> Blue wire -> Pedal micro-switch -> Green/White wire -> FNR micro-switch #1 -> White/Black wire -> Solenoid small post -> Red wire -> Controller Terminal #1.

Here is a better wiring diagram:




Edit:
If You have the solenoid yellow negative activation wire directly to negative and Controller terminal #1 has +48v when you press the pedal, the Solenoid is either bad or you are not wired like the diagram.
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Old 03-15-2018, 04:18 PM   #10
Mooncarter
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Default Re: Trouble with DS drive system.

The resistor nor the diode will stop it from running. You can't troubleshoot anything until you get your wiring straight per the diagram.
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