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Unread 12-21-2013, 09:43 PM   #1
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Red face Lost reverse, controller troubleshooting?

Today I replaced my battery cables with a 2 gauge set and the F & R switch with a HD model, all new parts from ScottyB. Quick shipping and good service, thanks.

I pulled all the batteries to clean the tray of old corrosion by products too. When I was pulling out the forward battery right under the driver's seat the posts touched the aluminum strip near the top of the opening. The pack was already disconnected and there were no cables on this battery at all. I've searched and read that the controller doesn't like any sparks and seems delicate. Since I don't recall how many wires were still connected to the controller it could have "sensed" the spark through the frame I guess.

After getting everything cleaned up, installed and back in the cart it goes better in forward now but not at all in reverse. I do get the buzzer and solenoid click but no movement.

Is there any troubleshooting of the controller I can do? Is there another possible culprit here or am I about to upgrade my controller too?

My cart is a 48 volt, 1995 DS Club Car with good batteries, about 20 months old.

Thanks for your time and help.
Have a very Merry Christmas,
Tim
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Unread 12-21-2013, 10:38 PM   #2
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Default Re: Lost reverse, controller troubleshooting?

Swap cables 5 and 8 at the F&R. They are they only 2 that have the small hole cable ends... If you then have reverse and no forward, you may have a defective F&R.

Let us know if you can test for continuity we can test the F&R.
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Unread 12-21-2013, 11:21 PM   #3
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Default Re: Lost reverse, controller troubleshooting?

Thanks Scotty. I'll make that test tomorrow and report back. How would I test continuity? Give me the steps and I'll give it a go.

Tim
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Unread 12-22-2013, 01:04 PM   #4
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Default Re: Lost reverse, controller troubleshooting?

I swapped cables 5 & 8 and the cart went forward while the FNR switch was in reverse and there was still no movement in the reverse direction when the switch was thrown the other way.

I then put my old FNR switch back in and had the same results; no reverse.

I checked all my cable connections again for snugness and found nothing loose. The S2 connection on the motor was tight and the stud was not moving.

All things are pointing to the controller aren't they?

If I have to replace it obviously like most on this site I'll upgrade. That's one reason why I went with 2 gauge cables anyway. Its likely a long shot but does anyone have a working, stock controller I can borrow to be sure? I'll pay shipping both ways or if you're close to SE TX or SW LA maybe we could meet.

Again, thanks for your time.
Merry Christmas

T
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Unread 12-22-2013, 05:58 PM   #5
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Default Re: Lost reverse, controller troubleshooting?

The good news is that the controller does not have anything to do with the reverse, it is all done by the FNR switch changing the current direction in the motor stator coil.
By reading your description and test results, the most likely cause is the motor wiring. Follow the cables that Scottyb told you to swap back to the motor, they are probably not connected to the correct terminals
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Unread 12-22-2013, 08:43 PM   #6
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Default Re: Lost reverse, controller troubleshooting?

Quote:
Originally Posted by Sergio View Post
The good news is that the controller does not have anything to do with the reverse, it is all done by the FNR switch changing the current direction in the motor stator coil.
By reading your description and test results, the most likely cause is the motor wiring. Follow the cables that Scottyb told you to swap back to the motor, they are probably not connected to the correct terminals
I agree with Sergio - his advice is always good.
Let us know if the solenoid is clicking in both directions
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Unread 12-22-2013, 09:59 PM   #7
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Default Re: Lost reverse, controller troubleshooting?

Yes, the solenoid does click with the pedal no matter if the FNR switch is in F or R.
I checked the wiring but this is good news so I'll be checking it all over again.

Is there a method to jump power directly to the motor to test it in both directions? Obviously with the rear axle lifted off the ground.

Thanks again for your help,
Tim
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Unread 12-23-2013, 08:15 AM   #8
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Default Re: Lost reverse, controller troubleshooting?

I have never seen a motor that would run in one direction and not the other.
So the fact that it runs in one direction tells us that the controller, solenoid, and the motor all worked. in the test for the SNR tells us that the FMR seems to be working. I think that leaves the cabling issue.
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Unread 12-24-2013, 08:26 PM   #9
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Default Re: Lost reverse, controller troubleshooting?

Thanks guys.
I figured out that when I was rewiring everything with the 2 gauge cables some dumb @$$ swapped the S2 and A2 cables on the motor. I'm going to have to fire that guy I guess but then nothing will get done.

I have a minor issue with the new FNR switch but Scott is already on top of fixing me up.

Now to just figure out my tire rub and then get the front bumper mount rewelded and beefed up.

I hope everyone has a great holiday season,
Tim
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Unread 11-02-2014, 09:41 PM   #10
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Default Re: Lost reverse, controller troubleshooting?

This is great information and i will check my S2 A2 but the question is ; Is there a diagram of the wiring? I had someone else put the new used motor in and of course there is no reverse in my 92 DS 36v. Maybe someone could direct me to a diagram? maybe in the sticky section?
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