94 Medalist charger wiring /activation circuit

[JohnnieB]

Just to verify. With the in-line connector unplugged and the 6-pin connector on top of the controller plugged in and the solenoid energized, the voltage on the black wire (pin-2 of the six pin connector on top of the controller, has 0.25V on it?

Also, verify that there is pack voltage on Pin-4 (Red wire) of the six-pin connector on top of controller. (That is what powers up the controller)

In addition, verify that the B- terminal on the controller is electrically connected to the main B- terminal on the battery pack and that the B+ terminal on the controller has full pack voltage on it when solenoid id energized.

If all of that is true, the controller is bad.

[knovak]

Yes on b-. B+ has pack voltage with light switch on. Harness connector on controller has pack voltage on red, 0 on orange and whit and black floats a bit at each test between.27 and 1.1

This confirms bad controller? Prior owner was able to bypass failing controller with the light switch until it completely failed?

[JohnnieB]

Originally Posted by knovak

Yes on b-. B+ has pack voltage with light switch on. Harness connector on controller has pack voltage on red, 0 on orange and whit and black floats a bit at each test between.27 and 1.1

This confirms bad controller? Prior owner was able to bypass failing controller with the light switch until it completely failed?

The orange wire is half-speed reverse and should be pack voltage when F/R lever is in reverse.

The voltage readings indicate the controller is bad.

The previous owner by-passed the solenoid activation circuit, which is external to the controller.
Normally, the contacts of four separate switches have to be closed to get the solenoid to click, he replaced them with the single light switch.

The controller going bad is a separate issue.

[knovak]

Thank you for all the guidance. I have a controller on order.

Now the bigger question - is there something or things that I should verify before installing this expensive part?

When I got the cart at least 2 cells of 2 batteries were dry so I am assuming it was run on lower voltage for awhile.

Thanks again for the help