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Unread 02-23-2019, 05:04 PM   #1
Not Yet Wild
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Default trouble diagnosing solenoid activation circuit

Cart
2001 48V DS Club Car Series
Complete 600 amp upgrade from www.cartsunlimited.net 1.5 years ago

Problem
The cart won't move, and the solenoid doesn't click. I started the diagnosis but got stuck. Here's a picture of my solenoid and my understanding of the posts:



Test 1
Voltmeter connected to posts 1 and 2
No pedal = 0V
Pedal pressed = 0V
This means that my solenoid activation circuit isn't working.

Test 2
I did step #2 of this website
voltmeter POS to solenoid post 2
voltmeter NEG to bat 6 NEG
no pedal = 0V
pedal = 48V
This means that "positive input is correct".

Test 3
I did step #3 of the website
voltmeter POS to bat 1 POS
voltmeter NEG to solenoid post 1
no pedal = 48V
pedal = 0V
I think my results are reversed from what I should get, but I'm not sure.

What do I do next? Any idea what's broken?
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Unread 02-23-2019, 05:10 PM   #2
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Default Re: trouble diagnosing solenoid activation circuit

Run a Jumper wire from your pack Neg and then to the small post where the Yellow wire is. Then try it. If it works, you have lost the Neg coming from the OBC.

To test you should have: Key On, Fwd selected, Go Pedal depressed. (cart jacked up for safety)
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Unread 02-23-2019, 05:33 PM   #3
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Default Re: trouble diagnosing solenoid activation circuit

Quote:
Originally Posted by NoleFan4Ever View Post
Run a Jumper wire from your pack Neg and then to the small post where the Yellow wire is. Then try it. If it works, you have lost the Neg coming from the OBC.

To test you should have: Key On, Fwd selected, Go Pedal depressed. (cart jacked up for safety)
Did the test, and the solenoid clicked. Wheels turned. Thanks.

What's the next step?
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Unread 02-23-2019, 05:51 PM   #4
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Default Re: trouble diagnosing solenoid activation circuit

Quote:
Originally Posted by ticklechicken View Post
Did the test, and the solenoid clicked. Wheels turned. Thanks.

What's the next step?
I'm attempting to answer my own question. Based on this website, I can
...add a 10 fuse to a 18 gauge wire and place this wire and fuse to the vacated solenoid terminal and to a battery negative connection. At this point computer replacement is not necessary. However, if you wish to retain the “lock out” function you must replace the computer.

So basically replace the test jumper I used with an 18 gauge wire with a 10 amp fuse. Only issue with this solution is that the drive system won't be locked out while charging. That doesn't bother me.

Sound correct?
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Unread 02-23-2019, 06:14 PM   #5
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Default Re: trouble diagnosing solenoid activation circuit

It is just that the Neg (Yellow) wire was supplied by the OBC and when charging it will not supply that. I have never fused one before as it is just the Neg between the solenoid and pack.

You need to monitor your OBC and make sure you have the 5-10 second delay when you plug in the DC receptacle and that is cuts off as it should. Usually when the OBC starts to fail, it continues that way over time.....
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Unread 02-23-2019, 06:40 PM   #6
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Default Re: trouble diagnosing solenoid activation circuit

Quote:
Originally Posted by NoleFan4Ever View Post
You need to monitor your OBC and make sure you have the 5-10 second delay when you plug in the DC receptacle and that is cuts off as it should. Usually when the OBC starts to fail, it continues that way over time.....
I just tried the charger and it won't charge the cart. I didn't think it mattered, but I tried charging with and without the jumper wire. Either way, it doesn't charge.

So...new computer?


EDIT - I'm resetting the OBC now
EDIT 2 - resetting the OBC didn't change anything
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Unread 02-23-2019, 06:56 PM   #7
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Default Re: trouble diagnosing solenoid activation circuit

(In case Nole is taking a nap) If the OBC is bad I would bypass it and replace the charger.
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Unread 02-23-2019, 07:08 PM   #8
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Default Re: trouble diagnosing solenoid activation circuit

Quote:
Originally Posted by Mooncarter View Post
(In case Nole is taking a nap) If the OBC is bad I would bypass it and replace the charger.
What's the advantage of that route instead of just replacing the stock OBC? What's the cost difference?
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Unread 02-23-2019, 07:24 PM   #9
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Default Re: trouble diagnosing solenoid activation circuit

MC was describing you a way to get you going for now and the better selection for New.

Here is the OBC https://www.revolutiongolfcars.com/p...8-04-ds-series

Here is the best charger (does not need an OBC) https://www.revolutiongolfcars.com/p...rger-13-18-amp

The OBC is good, but 25 year old technology. The Summit II is the best smart charger on the market....

And yes, I am headed out and will not be around.... Good Luck with whatever you do.....
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Unread 02-25-2019, 03:52 PM   #10
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Default Re: trouble diagnosing solenoid activation circuit

Hi Chip, thanks for contacting me.
I have the Lester Summit II suggested in that thread. It is our best charger.
Our price is $305 plus the round 3 pin cord for $46.25 = $351.25
These parts are in stock ready to ship > http://www.cartsunlimited.net/lester-summit-ii.html
If you are handy you can buy the charger alone for $305 and cut the old cord off the old charger and save some money.
Let me know if you have any questions
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