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Unread 08-01-2012, 01:45 PM   #1
Not Yet Wild
 
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Default 2007 48V no run/charge issues. kind of lengthy.

Im working on a 2007 electric right now, and ill have you know that it ran just fine and charged normally when i brought it into the shop.

during a lift kit install, the axle/motor assembly rotated forward after the u-bolts were removed from the leaf springs. i removed the wiring from the motor, and carried on.

finished the lift kit, put the wheels on, went to take it for a ride after i lined it up, and didnt go anywhere. the solenoid is clicking like it should, all the wiring is hooked up to the controller securely and the motor is hooked up and visually sound.

after some searching this forum, found that i could do a roll test to see if the speed sensor got damaged, since the wires for that basically caught the motor when it rotated forward and dropped. rolled it, got no rollaway beeps, and no motor braking.

verdict: faulty speed sensor. even did more searching to confirm. got another speed sensor, swapped that out, still having the same issue. no rollaway alarm, no braking, no starting, but the solenoid is still clicking over.

also noticed at this time that the charger isnt working either. fuse is good. attempted to reset the OBC, after removing the negative pack cable, key on in run, reverse, no buzzer at all. from what i read there should be the reverse buzzer, then that'll die, draining power from the system to reset it.

so im guessing resetting didnt work. bypassed the OBC and hooked the charger up, the relay inside clicks but it wont charge still. so only a little progress.

tried to jump the solenoid, no luck, same issues.

i dont know where else to go with this cart. it was supposed to be finished over a week ago and i've been trying to find new ways to trouble shoot since i finished the lift kit.

any input or advice is greatly appreciated. thanks everyone in advance, ill be checking for replies

-Aaron
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Unread 08-01-2012, 02:37 PM   #2
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Default Re: 2007 48V no run/charge issues. kind of lengthy.

DS or Precedent?
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Unread 08-01-2012, 04:57 PM   #3
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Default Re: 2007 48V no run/charge issues. kind of lengthy.

my bad, DS. yes.
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Unread 08-01-2012, 07:02 PM   #4
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Default Re: 2007 48V no run/charge issues. kind of lengthy.

Your problem is definitely not a speed sensor. A bad speed sensor will keep it from going full speed, not from running at all. Even if you completely remove it, it will still run. As for the charger. It's clicking because the cart is telling it to turn on. Make sure you've got power at the AC wall outlet.

Were your batteries unhooked when you did the lift kit install? I'm wondering if you didn't arc some wiring under the controller cover when this happened. Usually when this happens, the S1 and S2 wires (Blue and Orange) will come unplugged from the controller and cause this exact symptom.

When you bypassed the OBC, what procedure did you use to do so? The fact that the solenoid would click immediately after the lift kit install, but now it won't do anything concerns me. Hope you didn't fry anything.
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Unread 08-02-2012, 06:11 AM   #5
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Default Re: 2007 48V no run/charge issues. kind of lengthy.

my money is on a blown
controller
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Unread 08-02-2012, 09:31 AM   #6
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Default Re: 2007 48V no run/charge issues. kind of lengthy.

did you do anything with cables when you had it? is the last neg. cable still going thur hole in OBC? if not it has to...............i can,t see the controller having anything to do with charger so i would more to something with OBC.........................................
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Unread 08-02-2012, 02:21 PM   #7
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Default Re: 2007 48V no run/charge issues. kind of lengthy.

the wires are still all there, and the one going through the OBC is still going through it. its got a current sensor or something in there.

when the motor dropped, it did pull the orange wire off of the slide/spade connector at the controller, couldve been the blue one.

i want to say when i was doing the lift kit, the batteries were undone, but i may have not undone them til after the motor already dropped. at that point i took the wires off the motor, and had the batteries disconnected prior to that.

bypassing the obc, i jumped from the fuse holder behind the charger receptacle to the negative terminal at the end of the battery pack. hooked up the charger, the relay clicked in the charger but it still wouldnt come on to charge.

the reason i put another speed sensor on would be the "roll test" i kept reading about on here. with the key on and in forward position, push the cart and it should do some engine braking and do that rollaway alert noise. but it didnt do either of those, which was supposed to be the speed sensor.
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Unread 08-02-2012, 06:12 PM   #8
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Default Re: 2007 48V no run/charge issues. kind of lengthy.

Sounds to me like you need a controller.... The procedure you used to bypass to OBC does nothing but force the relay to click. It doesn't make the OBC close the internal connection and begin to charge. Especially on a 2007 DS. This was possible on the old cream color OBCs but the new grey ones won't allow it. The proper way to bypass the OBC to make the car run is to unplug the 6 pin connector and jump the red to the blue wire.
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Unread 08-02-2012, 06:24 PM   #9
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Default Re: 2007 48V no run/charge issues. kind of lengthy.

Is it possible some damage was done to the motor terminals if there was lot of tension on the wires? Might check to see if the motor terminals are getting power when when you mash the go pedal.
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Unread 08-03-2012, 03:58 PM   #10
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Default Re: 2007 48V no run/charge issues. kind of lengthy.

ill bypass your way in just a minute, thanks for the help, keep it coming hahah

there may have been damage to the terminals, but the only wires that really got tension were the three for the speed sensor. when the motor dropped the first time, i undid all the other wires to keep it from happening again.
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