Trying to get my 2002 club going

[Sergio]

That was the wiring diagram I posted for You, it appears to be the one that matches your components.

You have powerdrive plus components, not an IQ.

The brown and orange/white are the wires for the DB solenoid that you do not have. Since there was a mid year production change that removed the DB solenoid, it is entirely possible that ClubCar did a hack job in the harness to accommodate the changes. That also explains that harness loom that has no wires in it, it was probably for the DB solenoid. You would have to have confirmation from one of the pros that has actually worked on those years to verify that.

Just to be safe, unplug the speed sensor from the Motor.

Make sure you keep the rear wheels off the ground while testing it.

By-pass OBC activation circuit:

• Put cart on Tow
• Disconnect 6 ping plug from OBC
• Put a jumper between "White" and "Blue" wires in the harness side of OBC.
• Put cart on run

By-Pass OBC Charging Circuit:

• Charger receptacle positive to pack positive
• Charger receptacle negative to pack negative
• Charger receptacle "Sense" (gray) wire to pack negative
• Plug charger in, it should run but never turn OFF
• Disconnect charger when pack reaches 60v

Make sure the rest of the wires match the diagram.

Did You ever tested the motor?

[todleb64]

Sergio:
Thanks for all your help....

Yes, I did test the motor, it worked just like you said...

I put a new recepticle, and I still have 51volts across battery pack.

I believe I done that BY-PASS activation, I think you told me that, as for as this,
By-Pass OBC Charging Circuit:
Charger receptacle positive to pack positive
Charger receptacle negative to pack negative
Charger receptacle "Sense" (gray) wire to pack negative
Plug charger in, it should run but never turn OFF
Disconnect charger when pack reaches 60v

Do I discconect the wires from the recepticle, and attach as such?

[CCFanatic]

Sorry for getting here so late. Anyway, I was able to dig up for service manual that goes along with your electrical system. Ignore the year, the electrical system is just like the one in your cart

[todleb64]

CC:
It seems as though the Dynamic Braking Solenoid was removed from the cart, that explains the orange/white and the brown wires, now on the potentiometer, I have a MCOR on mine, this is crazy....I t would sure be nice to have this this cart move, like it did when I did that motor test.....

[CCFanatic]

There was no MCORs on the PD Plus cars. That must have been on the frame, which is from 02. Just out of curiosity, does the F-R housing have a port on the bottom of it?

Here is my guess, the cart was originally an 02 IQ. It looks like the IQ controller went out and a DIYer decided to stick a PD Plus controller in there. And changed some things for it to work

[Sergio]

In 2001-2002 there was a powerdrive plus with an MCOR, that is where I got the diagram I posted.

The disconnected wires I am guessing are a result of the mid year change from DB solenoid to not having one. I would recommend disconnecting the speed sensor in case that this is not the case and a previous owner removed the solenoid.

If the solenoid clicks when You step on the go pedal:

• Remove the resistor from the solenoid
• Set your meter to 200vDC
• Place the negative probe on the pack negative.
• Test both BIG solenoid posts, You should have 48v on only one side (Battery side)
• Put the positive probe on the side with 0v (controller side)
• press the go pedal, You should have 48v now.

If the above works, check the MCOR voltage for proper range.

[mrgolf]

That is what I think also.

I have listed all the changes I have done to my cart and keep them in a ziplock bag under the seat. If someone ever gets my cart they will have something to work with. First thing they would do is get rid of the seat and all those stupid papers.

[todleb64]

The F-R, that is where the rocker switch is correct, I will look tonight, it looks like I have a Franken cart!!! What do you think i should do?

[Sergio]

To test MCOR Voltage:

• Set meter to 20vDC
• Put negative probe on pack negative
• Put positive probe on Yellow/Black (Controller pin #7) using insulation piercing probe
• Reading should be 0.32v Pedal up to 4.65v Pedal down.

[Sergio]

Originally Posted by todleb64

The F-R, that is where the rocker switch is correct, I will look tonight, it looks like I have a Franken cart!!! What do you think i should do?

You have new batteries
You have 10HP Sepex Motor that works
You have an MCOR

I would get with ScottyB, buy an IQ harness and an IQ controller and You will have a nice setup.