2002 DS Electrical Issue

[Zlockett2147]

So I am new to the scene and I bought a 2002 DS AQ0243-218833 and I replaced all 6 Batteries, have 48.8V from the Battery Last neg to Battery last Positive. It was a wiring nightmare when I got it and I stripped all accessory wiring and wanted to start fresh. When I flip the switch to run, I have no power/response. When I put the cart in reverse I have no chime, and no solenoid click when trying to operate the cart. Any suggestions on where to start or where to find a good troubleshoot manual? Apologies in advance if there is already a thread for this but I am new to the forum and unsure how to search!

[Mooncarter]

[NoleFan4Ever]

Welcome!

[NoleFan4Ever]

Originally Posted by Zlockett2147

-snip-
Any suggestions on where to start or where to find a good troubleshoot manual?

Do the following: (with one wheel jacked up) Get your DVM and place the Black probe on the pack Neg and then with the key On, cart in Fwd, and Go Pedal depressed far enough to hear the microswitch click, take the Red probe and check to see if you have pack voltage in the following pins at the controller: Pin 5 - Lgt Blue, Pin 6 - Green, Pin 8 - Brown, Pin 9 - Grey, and Pin 10 - Tan.

[Zlockett2147]

Originally Posted by NoleFan4Ever

Do the following: (with one wheel jacked up) Get your DVM and place the Black probe on the pack Neg and then with the key On, cart in Fwd, and Go Pedal depressed far enough to hear the microswitch click, take the Red probe and check to see if you have pack voltage in the following pins at the controller: Pin 5 - Lgt Blue, Pin 6 - Green, Pin 8 - Brown, Pin 9 - Grey, and Pin 10 - Tan.

I have 49.8v at all of the above mentioned except pin 6 light green I have 13v

[NoleFan4Ever]

That signal comes from the MCOR MS. But you should have still had the reverse buzzer....

Try this. Unplug the two pin connector from the MCOR (under the floor and connected to a linkage from the pedal) and jump out the connector with a paper clip or a small piece of wire. It will be a blue wire and green wire connector. If it runs with the jumper in place, your MCOR MS has failed. If it does not, we will look further.

[Zlockett2147]

Thank you, I will try this. Just FYI , some of the wires from the electric motor to the controller were not hooked up correctly. Someone had reversed them. Not sure if that can fry the controller or not.

[NoleFan4Ever]

This is the correct drawing for your cart.

[Zlockett2147]

I have no response on the Mcor when I jump it with the paper clip. I also have no buzzer when I switch to reverse. I don’t hear any clicking on solenoid either.

On a side note, when I plug the charger in, it takes about 5 seconds to click on. It will click on, spike to 10amps , and then trip the fuse on charger. I tried it again and it blew the fuse on the charging port in the yellow rubber holder. I’m lost.... lol

[Zlockett2147]

Originally Posted by NoleFan4Ever

This is the correct drawing for your cart.

I have no response on the Mcor when I jump it with the paper clip. I also have no buzzer when I switch to reverse. I don’t hear any clicking on solenoid either.

On a side note, when I plug the charger in, it takes about 5 seconds to click on. It will click on, spike to 10amps , and then trip the fuse on charger. I tried it again and it blew the fuse on the charging port in the yellow rubber holder. I’m lost.... lol