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Unread 09-01-2019, 08:35 PM   #1
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Default 95 DS 48v Will Not Run

Early 1995 48v DS with 0-5k v-glide. 50.9v pack. Rebuilt v-glide, smooth 0-5k at controller. Proper voltage at tab for controller power. New heavy duty FNR switch. New solenoid. New 2 gauge battery cables. All new microswitches. OBC removed.

Motor tested good. Solenoid clicks no go. Pack voltage on "hot" side of solenoid. Pack voltage at "cold" side of solenoid, at controller, and at motor A1 with FNR in N, pedal not depressed, key off, no resistor on solenoid. Tested no continuity at solenoid large posts, pack unhooked.

Key on, in F or R press go pedal and solenoid clicks. FNR, controller, and motor get warm.

What is going on? Usually I figure these things out. This one has me stumped.
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Unread 09-01-2019, 09:26 PM   #2
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Default Re: 95 DS 48v Will Not Run

Tested the motor separate?
The wires on the motor and FnR switch all connected right and no loose crimps?
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Unread 09-01-2019, 09:29 PM   #3
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Default Re: 95 DS 48v Will Not Run

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Originally Posted by Fairtax4me View Post
Tested the motor separate?
The wires on the motor and FnR switch all connected right and no loose crimps?
Motor was tested (twice) all cables unhooked from motor. Have checked cables condition and placement and am checking again now.
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Unread 09-01-2019, 09:42 PM   #4
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Default Re: 95 DS 48v Will Not Run

Just checked placement and continuity of all cables. All check OK.
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Unread 09-01-2019, 09:55 PM   #5
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Default Re: 95 DS 48v Will Not Run

Motor good, FnR good, throttle good, batteries good, solenoid good, controller gets warm so Something is happening but... sounds like a bad controller from here.
Have a spare?
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Unread 09-01-2019, 10:20 PM   #6
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Default Re: 95 DS 48v Will Not Run

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Originally Posted by Fairtax4me View Post
Motor good, FnR good, throttle good, batteries good, solenoid good, controller gets warm so Something is happening but... sounds like a bad controller from here.
Have a spare?
No. But I just found a bad (brand new) microswitch at FNR while testing things. Replacing it now.
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Unread 09-01-2019, 11:03 PM   #7
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Default Re: 95 DS 48v Will Not Run

Replaced it. Outermost micro for 1/2 speed reverse. Made no difference.

I am having to go back and forth between a diagram for a 36 volt controller cart with this same v glide throttle and no OBC, and the 1995 with the 3 wire 5k-0 potentiometer and OBC.

Neither shows everything I need to see and there are differences.

This exact cart was made for only about 3 months in early 1995. Does a wiring diagram exist for it? Having said that, The diagram I have been looking at (the very first diagram in the CC wiring diagram stickies) shows what looks like a 3 pin microswitch wired at the top and bottom which would, in my understanding kill the power when pedal is depressed. Any thoughts on this? I am pretty sure that's what I did. Which makes no sense because solenoid is clicking. Unless there is something in wiring which is only specific to this cart.
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Unread 09-01-2019, 11:58 PM   #8
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Default Re: 95 DS 48v Will Not Run

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Originally Posted by Fairtax4me View Post
Motor good, FnR good, throttle good, batteries good, solenoid good, controller gets warm so Something is happening but... sounds like a bad controller from here.
Have a spare?
Thanks FT. I would gladly replace the controller if I knew that was the problem. But it seems to me the motor is getting power (even with all this other stuff going on) and it won't run.

But, if I can't figure this out by tomorrow it's coming out and a new one going in.
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Unread 09-02-2019, 11:32 AM   #9
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Default Re: 95 DS 48v Will Not Run

Did you test the motor by connecting it to a battery to see if it would spin?
Or just check it for continuity?

If you hook a battery to the motor and it runs, then I would think the controller is the problem.
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Unread 09-02-2019, 11:49 PM   #10
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Default Re: 95 DS 48v Will Not Run

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Originally Posted by Fairtax4me View Post
Did you test the motor by connecting it to a battery to see if it would spin?
Or just check it for continuity?

If you hook a battery to the motor and it runs, then I would think the controller is the problem.
Sorry for the delay FT. Motor passed all continuity tests. 24 volt battery tested motor in both directions runs fine. Controller coming out tonight.

Thank you!
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