1999 DS Club Car Click NO GO

[rjrust]

This club just quit last year. SN#A9947-826535.
We have replaced the OBC, Controller, Solenoids, and the peddle controller.
When the key is turned on the solenoid click in and out. Tested all the voltages, and the motor. Continued to test the low amp side of the controller everything checks out except the negative output from the controller. When I place my test light on the last negative terminal and probe the yellow wire on terminal #6 of the controller the cart runs.

Short of opening up all the wiring harness for a broken wire thought I would check your thoughts on the next move.
Ideas?

Thanks

[Mooncarter]

What drive system do you have?

How many solenoids?

Sounds like it could be solenoid(s) not getting signal to activate. Need more info.

[rjrust]

This is a DS Club Cart regen 2.
2 solenoids
Main solenoid clicks in and out with the T/R switch on and have full voltage across all terminals.
The controller (original) was IC3645SH4D222C2, the replacement controller that is replace that one per the supplier is IC3645SH4D222C5. Looking at the wiring diagrams for both controllers they are different.
I suspect the controller is not for this configuration.

With the replacement controller my test light on clip on last negative post and probe the yellow wire of the controller the cart runs. The controller is not completing the negative output. Testing all signals to the controller are good.

Terminal 13 green wire is the difference between the wiring diagrams.

Just done changing parts until I have more information.

Any help is appreciated.

Thanks in advance

[biphase]

When you say that probing the "yellow wire" causes the cart to run, exactly which yellow wire are you referring to?

[Mooncarter]

Originally Posted by rjrust

This is a DS Club Cart regen 2.
2 solenoids
Main solenoid clicks in and out with the T/R switch on and have full voltage across all terminals.
The controller (original) was IC3645SH4D222C2, the replacement controller that is replace that one per the supplier is IC3645SH4D222C5. Looking at the wiring diagrams for both controllers they are different.
I suspect the controller is not for this configuration.

With the replacement controller my test light on clip on last negative post and probe the yellow wire of the controller the cart runs. The controller is not completing the negative output. Testing all signals to the controller are good.

Terminal 13 green wire is the difference between the wiring diagrams.

Just done changing parts until I have more information.

Any help is appreciated.

Thanks in advance

If you are calling the solenoid closest to the passenger side the main solenoid. Put both cables on the other solenoid (the large ones) on one post of that solenoid and see what happens.

[rjrust]

I'm probing the yellow wire from the OBC to the controller. With the probe light clip on the last negative post and I probe into that yellow wire the cart will run.

The solenoid on the passenger side, yes, I'm calling the main solenoid.
And you want me to bypass the regen solenoid with the big cables? (drivers side)

[Mooncarter]

Originally Posted by rjrust

I'm probing the yellow wire from the OBC to the controller. With the probe light clip on the last negative post and I probe into that yellow wire the cart will run.

The solenoid on the passenger side, yes, I'm calling the main solenoid.
And you want me to bypass the regen solenoid with the big cables? (drivers side)

Yes.

[biphase]

[QUOTE=rjrust;1817129]I'm probing the yellow wire from the OBC to the controller. With the probe light clip on the last negative post and I probe into that yellow wire the cart will run.

That would be pin 6 on the 23 pin plug. That is the pin the controller recognizes as the charger interlock. On MOST of the GE controllers that pin must be high (48v) to enable the controller. If the pin is low (0v) the controller thinks you have a charger plugged in. HOWEVER, there are some versions of the controller that require the exact opposite logic (low=go, high=stop). It appears that you have the latter type. When you probe pin 6 you are actually grounding it and thus the cart will run. You can permanently ground the yellow wire and the cart will run normally EXCEPT it will not be disabled when you have a charger plugged in.