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Unread 03-04-2011, 05:44 PM   #1
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Default 2001 DS new to me. No power except lights.

Just got a cart for summer ($1000), battery pack show 50v. Lights work, nothing else. I am new to the electrics and I am reading as much as possible on the forum all night. The only clicking I can hear is a black box under neath the frame connected to the gas pedal by a splined shaft. Sound like a micro switch inside that box. Behind the seat is what I believe to be the OBC on the left, a controller in the middle and a relay on the right. I have 50v on one side of the relay that connects to the batt pack. When I probe the small terminal marked + in the relay, I get .2 volts and I see what looks like an overheated resistor. Any ideas I should check first that might get this baby going? On the charger, it appears to charge but only shows 1/2amp on the meter. When it is plugged in the voltage of the pack creeps up to about 55 and I shut it off till I can tell if that is faulty or giving me a faulty reading. Looking for some help while I read for more info to troubleshoot. Thanks for any help!

Series motor, F/R lever. No tow run switch.
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Unread 03-05-2011, 07:10 AM   #2
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Default Re: 2001 DS new to me. No power except lights.

I seems like the relay is not energizing when I step on the pedal. No click and no voltage going across solenoid. Am I right in assuming that this should be clicking and sending current to the controller? Or should I be looking at the F&R switch. Is there a certain order that I should be going in to follow my power through the different "black boxes"? Thanks again.
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Unread 03-05-2011, 10:08 AM   #3
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Default Re: 2001 DS new to me. No power except lights.

I probed the relay and found when I used the neg probe on either of the small terminals and the pos probe on the pos terminal of #1 battery I had pack voltage on both small terminals of the solenoid.
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Unread 03-05-2011, 10:47 AM   #4
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Default Re: 2001 DS new to me. No power except lights.

Sorry need more cart info? Does it have a lever operated F&R under right leg, or a rocker type switch F&R control in same location? This give forum type of motor and controls you have.
The click you hear is coming from the MCOR speed control is a mechanical sound rather than a electronic sound but is needed as part of inline sequence of operation. But there are many parts that require voltage before a cart can operate.
Was cart working correctly when first purchased? Have you done a battery cable contact removal and shiny clean and tight surface clean up? ( IF your cart has TOW-RUN SWITCH ALWAYS TURN TO TOW BEFORE DOING ANYTHING TO BATTERYS OR CABLES OR ANY WIRING or damage might be extensive? )
To do tests you must first be sure that you have full power going to specific locations depending on which model cart you have. Test digital meter can show proper voltage when only a tiny amount of battery connections are in place. Its like checking a auto for carb problems when its only a bent gas line? Once you have confirmed good connections and tested each battery ( 8.49 volts ) as well as pack voltage ( 50.96 volts ) then forum can walk you through tests.
To jump ahead and start guessing which part is bad I find is a waste of everyones time?
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Unread 03-05-2011, 12:05 PM   #5
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Default Re: 2001 DS new to me. No power except lights.

Thanks for the reply. I did mention the pack voltage was 50, being a series motor with a F&R lever, no tow/run switch. Batteries are new and all connections are clean. Cart was not working, I saw all battery cases were bulging out at the ends so I bought new batts. 48v sys, batteries are between 8.1-8.4 Connections clean and tight with dielectric grease applied. So far, seems I am NOT getting voltage to the positive side of the solenoid with key on, selector in fwd and pedal down. I apologize for not being as specific as I could have been, and do not want to waste anyones time.
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Unread 03-05-2011, 01:13 PM   #6
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Default Re: 2001 DS new to me. No power except lights.

This is probably not your only problem, but your batteries are at about 60% charge. Look at the stickies at the top of this forum and you will find the "state of charge". Read this and you will see what I am talking about. You need to hook up the charger, assuming it is the factory one, and let it charge until it stops itself. This could take up to 16 hours+/-.
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Unread 03-05-2011, 01:24 PM   #7
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Default Re: 2001 DS new to me. No power except lights.

Well, another problem... when the charger is plugged in I can hear/see the water boiling in the last 2 batteries and my ammeter on the charger reads 0. I will plug it back in and beings I wont leave it unattended, will make sure they dont overheat. Thank you for your help MEC and dtkana.
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Unread 03-05-2011, 04:16 PM   #8
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Default Re: 2001 DS new to me. No power except lights.

To start with most golf cart batterys have swelling as normal condition SORRY?
DTKANA is correct about amount of battery charge, and as he said its not the whole cause of your problem but needs fully charge to help with battery break in period ( SEE STICKIES UNDER HEADING "Battery Guide" and "State Of Charge Readings".
For a gas auto person using a single battery to start engine ( 3-10 Seconds ) and long re-charge time to run accesories with a high output alternator ( 50-120 amps ). Where a electric car or golf cart depends on a completly different draw off a bank of batterys, that are built completly different for a different function . Auto batterys only last minutes ( even deep cycle ) and will have very short life in constant cart operation.
As to batterys boiling this can be normal with new batterys and does depend some what on quality of batterys ( heavier weight normally means more lead meaning longer range-life span, available power acts like sponge ) and how much distilled water is used ( 1/4" above plates after charging and allowing to cool ) and depends on operation of charger. With a stock Club Car charger with OBC every time you interupt the cycle ( unplug charger ) the OBC starts all over again and can duplicate cycles causing high charge rates. For good info on OBC functions go to forum member DrBob site.
As said before low batterys are not all of your problem so I will give you a sequence of operation. battery pack plus post to solenoid large post with 6 guage cable, then tapped by green wire to Key switch, to Blue wire to micro inside MCOR under passenger floor "pedal down", to Green wire with white stripe to Micro on back of F&R control ( neutral switch nearset F&R from back side ), to white wire with black stripe, to solenoid activation coil, to yellow wire ( other side of activation coil ) to OBC to complete ground back to pack ground, this completes the circuit and closes solenoid.
Hope this helps.
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Unread 03-05-2011, 06:32 PM   #9
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Default Re: 2001 DS new to me. No power except lights.

Thanks MEC that info will help alot. When I looked inside the batteries the electrolite was cloudy and the plates were wavy, so I went with new. I wish I had a known good charger with a working gauge to see if the amps were coming down. My multimeter only goes to 10amp fused, so I gotta be careful. Thanks again for your help!
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Unread 03-06-2011, 08:55 AM   #10
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Default Re: 2001 DS new to me. No power except lights.

Thats what forum is for so remember to pass it on to the next person what you have learned. Keep forum in loop with updates on what you find.
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