03 CLUB CAR no run

CaptRon60

just picked this up not running, have 50 volts at pak, no solenoid click have power to small wires when key on, hit pedal hear micro switch click have power coming out on blue wire at mcor. have replaced controller and solenoid, jumped the white and blue wire to OBC have power at tow run switch and red and white wire at FNR switch, Im at a loss....serial # AQ0320-284079...ANY HELP WOULD BE APPRECIATED

BGW

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Fairtax4me

Do you have power coming out of the FnR switch? If you put it in reverse does the buzzer sound?
You do have 48 on both small terminals at the solenoid? If so controller is not giving negative command to activate the solenoid.
Pretty sure controller needs Key On, F or R selected, and throttle pressed to activate the solenoid.

CaptRon60

after bypassing OBC I have reverse buzzer, when key on I have pak voltage on both small terminals just not to yellow on big terminal hitting accel makes no difference

Fairtax4me

You have voltage on both small terminals at the solenoid because it is not getting ground command from the controller. When the controller provides the ground for the solenoid the voltage will drop on one side and the solenoid should engage.

If the reverse buzzer sounds then the controller is getting signal from the FnR switch, so we need to make sure it is also getting signal from the throttle microswitch in the MCOR.
This diagram should be pretty close to what you have:


Check pin 6 at the controller, should be a Green wire. You need 48v there with key On, pedal pressed.

CaptRon60

OK verified 48 volts at Green wire with pedal depressed

Fairtax4me

OK how about at pin 9 Gray wire, should be 48v with Tow run switch in Run.
Pin 10 Tan wire, should have 48v with Key On.

And you still have White and Blue jumped together at the OBC?

CaptRon60

Verified grey and Tan, and yes have OBC bypassed still


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Fairtax4me

Then unless there's a loose connection/ loose pins in the 16 pin connector, sounds like the controller is dead. Where did you get the new controller? Was it brand new or refurb?

Do not install another controller until you check the motor for short circuit. Put cart in Tow and disconnect the pack negative and positive.
Check the Cables on the motor make sure none of the cable ends are touching each other or any part of the motor case. If any cable ends touch each other this will kill the controller when it is powered up.
Remove the cables and check the motor for continuity from A1 to A2, and F1 to F2. Should have continuity.

Check for continuity from both A to both F terminals, these should NOT have continuity.
Check for continuity from All terminals to the motor case. You should have NO continuity to the case.
If it fails any of these the motor has an internal short and is killing the controller.

CaptRon60

Will do thanks ,bought the controller new from Buggies unlimited


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CaptRon60

Have continuity between A1 and A2


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