2002 Club Car DS just stopped after installing 2 gauge wires

[seeyalatergator]

Ok. The charger cut off over night. Didn't have time to check voltage this morning before work. I did unplug the charger and tried to see if it would move. It would not. No click, no nothing. Where do I need to go from here?

[Sergio]

To troubleshoot the Solenoid Activation Circuit on a 2002 DS Series cart:

The yellow wire on the solenoid small post goes to the OBC and provides the negative for the Solenoid.

The White/Black wire on the solenoid small post goes to the FNR micro switch, Pedal switch, key switch and provides the positive for the Solenoid.

Lift one wheel off the ground, turn the key on, put FNR in Forward and press the pedal.

Set meter to 200vDC scale.

Measure the voltage across the solenoid small posts: Yellow (meter negative probe) and Black/White (meter positive probe) wires.

If You get +48v and the solenoid does not click, replace the solenoid.

If You don't get +48v, find out which side is missing:

Measure the voltage between the pack negative battery post (meter negative probe) and the Black/White wire (meter positive probe) at the solenoid small post.

If You don't get +48v, the micro switch in the FNR or the Pedal micro switch is the problem.

Measure the voltage between the pack positive battery post (meter positive probe) and the yellow wire (meter negative probe) at the solenoid small post.

If You don't get +48v, the OBC lockout is the problem. You can disconnect the yellow wire from the solenoid and ran a new 16ga wire from that solenoid small post directly to pack negative or Controller B-

[seeyalatergator]

Thanks Sergio, I will do that this afternoon when I get home and post results.

[seeyalatergator]

Ok. According to Sergio ' s diagnostic procedure, either the micro switch in the FNR is the problem or the accelerator pedal. I know where the FNR micros are. Is the accelerator switch in the box on the frame rail?

[seeyalatergator]

Or are you saying one of the micros is the pedal switch?

[Sergio]

Yes there is a micro switch inside the Vglide, the pie shaped box referred to as a Multi-Step potentiometer.

Power comes in from the key switch on the Blue wire and the switch completes the connection to the Green/White wire that goes to the FNR micro switch.

The FNR micro switch completes the signal from the Green/White wire to the White/Black wire that goes to the Solenoid to provide the positive activation side of the circuit.

Check the FNR micro switch first since it is the easier one to access.

[seeyalatergator]

Ok. I'll check that.

[seeyalatergator]

This is a dumb question, but where do you put the negative probe when checking the FNR micro for voltage? If I grounded it correctly I am not reading any voltage at the FNR switch. It got dark on me, so I will have to investigate more tomorrow.

[scottyb]

Hey CC gets sneaky sometimes and puts negative to those little circuits so try it with the 'other' lead on + and - at the F&R and then if you find juice there going through the switch move to the V glide and repast the process per Sergio's instruction.

[Sergio]

I added the model and year to the top of the first post to make sure other folks knew the specific model this applied to, because as scottyb mentioned, there are quite a few differences in some model years.

I think I will start adding this to every set of instructions:

• If the colors below do not match your cart, stop and ask for clarification before proceeding.
• Unless otherwise noted, all voltage readings are in reference to pack negative or B- (meter negative probe placed there).
• +48v is a nominal voltage and means actual pack voltage.

Disconnect the Green/White at the FNR micro switch and measure the voltage on the wire

If You get +48v on the Green/White wire with Key ON and Pedal pressed:

That micro switch is either bad or the FNR cam is not pressing the lever on the switch.

You can set your meter to "continuity" and test the terminals on the switch to make sure they close (You get a continuity beep from the meter) when the FNR is moved from neutral to either Forward or Reverse.

Pay attention to the switch as sometimes folks will replace a 2-terminal switch with a 3-terminal switch. In that case You need to use the Normally Open terminals on the switch.

If You do not get +48v on the Green/White wire:

Check the Blue wire on the Multi-Step potentiometer, You should get +48v when the Key switch is ON.

If You get +48v, the micro switch inside the Multi-Step potentiometer is bad.