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Unread 05-16-2018, 06:29 AM   #21
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Default Re: 2003 Club Car w/ Solid State Conversion Kit Won't Go

Quote:
So both the Solenoid and the Reversing Contactor are still clicking as You press the pedal?
Yes, they are clicking. I followed scotty's procedure for checking the solenoid below. Without the pedal pushed, I read 50V from the main neg to the big pos terminal. In the last step, when I move the lead to the big neg terminal, I only read 1.9V. Then when I push the pedal, I read 10V.

Here are the controller codes: 3 green initially, then 1 green, then 1 green+6 red which seems to indicate pre-charge failure (B+ voltage and KS1 voltage differ by more than 5v. Stuck solenoid.) I guess this is the 10V vs 50V difference?

Solenoid not working

How to verify the solenoid is actually working?

Remove the pre-charge resistor from the big terminals.

Put the voltmeter black (common) on battery main (-) and the red lead on the solenoid big terminal with the battery Main (+) cable on it

The voltmeter should read the same as the battery pack here.

Now press the pedal so the solenoid clicks and move the red lead to the other big solenoid post = this should also now read the same as the battery pack.
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Unread 05-16-2018, 08:59 AM   #22
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Default Re: 2003 Club Car w/ Solid State Conversion Kit Won't Go

If You don't have the pre-charge resistor on top of the Solenoid You will get a "pre-charge failure" from the Controller.
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Unread 05-16-2018, 09:01 AM   #23
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Default Re: 2003 Club Car w/ Solid State Conversion Kit Won't Go

I re-attached the resistor before that.
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Unread 05-16-2018, 09:03 AM   #24
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Default Re: 2003 Club Car w/ Solid State Conversion Kit Won't Go

As Sergio said removing the pre-charge resistor will cause a precharge failure. After testing the solenoid and confirming it is working ?
Put the resistor back on.
Post some pics of the solenoid wiring.... no closeups please. Maybe we can see what's wrong.
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Unread 05-16-2018, 09:11 AM   #25
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Default Re: 2003 Club Car w/ Solid State Conversion Kit Won't Go

Quote:
Post some pics of the solenoid wiring.... no closeups please. Maybe we can see what's wrong.
Thanks Scotty and Sergio. I will post pics of the solenoid wiring in a bit.













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Unread 05-16-2018, 01:52 PM   #26
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Default Re: 2003 Club Car w/ Solid State Conversion Kit Won't Go

Bump for new pics added.
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Unread 05-17-2018, 08:23 AM   #27
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Default Re: 2003 Club Car w/ Solid State Conversion Kit Won't Go

Everything looks fine to me.

Put the FNR in Neutral and make sure the Solenoid is "clicking" (the Reversing Contactor is loud and may mask the sound).

If the Solenoid is "clicking" but the voltage on the Controller side of the Solenoid is not raising to pack voltage, the Solenoid contacts are stuck or burnt.

It would be helpful if You used different color wires or just used color tape on the end of the wires to help identify them from each other.
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Unread 05-17-2018, 12:16 PM   #28
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Default Re: 2003 Club Car w/ Solid State Conversion Kit Won't Go

Quote:
If the Solenoid is "clicking" but the voltage on the Controller side of the Sotlenoid is not raising to pack voltage, the Solenoid contacts are stuck or burnt.
What could cause a new solenoid to get stuck or burnt in such a short time, aside from pure failure?
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Unread 05-17-2018, 01:26 PM   #29
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Default Re: 2003 Club Car w/ Solid State Conversion Kit Won't Go

Wiring the solenoid on for 10 hours can cause coil failure.
Reversing polarity can also cause failure. The install diagram calls for one wire from Battery Main + to the key switch. Where is the other small wire you have on Battery + going to?

It looks like you have a wire going from controller B+ to the solenoid coil. And it looks like you have a wire going from controller B- to the solenoid coil.
It's a bit hard to see with every wire being red.
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Unread 05-17-2018, 02:02 PM   #30
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Default Re: 2003 Club Car w/ Solid State Conversion Kit Won't Go

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The install diagram calls for one wire from Battery Main + to the key switch. Where is the other small wire you have on Battery + going to?
That's the 10g wire to the charging port.

Quote:
It looks like you have a wire going from controller B+ to the solenoid coil. And it looks like you have a wire going from controller B- to the solenoid coil.
Yes, I have a wire going from controller B+ to the solenoid. The three wires connected to controller B- are going to (1) the reversing contactor, (2) battery main-, and (3) the pedal throttle (black wire). No wire from controller B- to the solenoid coil.
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