No reverse, 2002 48V Series CC.

Rockybay65408

2002 48V Series CC
Hi, long time lurker, first time posting.
Can anyone help me verify that the controller is good or bad?
I've searched through 500 posting looking for an answer but I guess I need some friendly help.
I suspect that the controller is bad but want to be sure before replacing it as I'm in the Bahamas and nothing is easy or cheap except the rum.
The cart runs fine in forward.
In reverse, the solenoid clicks and the shunt resistor gets quite warm, but no motion.
In the course of trouble shooting this I've replaced all corroded connectors and the nuts and bolts on the controller that fasten the wiring.
The wiring to the controller is in very good condition.
The F/R micro switch is good and I swapped the white & black wire (at the reverse micro switch) to rule out the limiting resistor being open.

While I'm grateful for the wiring diagrams, I'm unable to make much out of them due to the limited resolution and the pictorial style used. Much more comfortable with a wiring schematic.
In a posting I can no longer find, someone suggested swapping two of the small gauge spade connections at the controller to check that the motor will actually go in reverse.
Not about to try this from memory and anyway the color code of the wires he mentioned are not the ones I have.
Sorry for the long posting, thanks in advance.

Harry

BGW

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scheek

I'm in the same situation with my 99 DCS Ez Go. I did about the same things you have done. I used my ohm meter to check to make sure I was getting voltage to the micro switch. That done try to verify continuity of those two wire back to the controller to make sure there is not a short in the two wires. Check and make sure wires are in good shape to your motor.

After that take to a shop. It was worth the short visit to verify the controller was bad. They did not charge me anything for a quick look. I did purchase the replacement controller from them. Tip: they have access to refurbished controllers that carry a one year warranty.

Good luck.

TahoeDawgZ71

Take the F&R Switch off of the car. Look at the copper contacts on the front of it (the ones you can't see without removing it) There's a blue wire, and a white wire hooked to the front of it... It's probably melted. Replace F&R Switch if so. To check the motor for reverse operation... swap either the A1 and A2 posts on the motor or swap the 2 wires on the F&R switch that are mounted to the pivot nuts.

Rockybay65408

Hello David and many thanks for your kind reply.
I didn't pull the F&W switch because I may have to destroy it to get it out and will wait until I have replacement in hand before proceeding. At the very least I will have to drill out the screw on the handle. Everything rusts or corrodes here. The good news is a friend has a spare on the island.
I did swap the two cables on the pivot nuts and the cart runs fine in reverse, I hope that signifies that every thing aft of the switch is working.

Harry

Rockybay65408

I replaced the F/R switch and all is fine. Thank you very much.
For other non techs like me I add the following.
Looking at the switch, even after it was removed, it did not at first glance appear faulty.
A closer look however and I could see a spot where melted plastic or pushed up wear formed a small ridge that would lift the wiper just slightly off the contact, breaking the connection. If it was necessary and if I wasn't forced to cut the handle off the switch, I could have removed the offending ridge and it would have served until a new part could be procured.
I would suggest to others that the handle be removed occasionally, if still possible, and lightly lubricated against the day the switch needs replacing.
I've replaced all of the switch hardware with stainless steel, but that's just a normal need of my location.
Harry