Help with 2005 Carryall 2 electric

[FRC Dave]

If this is the wrong place for a carryall, please let me know. I have a 2005 carryall 2, serial number E0508-482661 that won't go in reverse. The closest maintenance manual I have is for a 1997. Motor is made by Advanced Motors & Drives. There are 2 part numbers, 7175 and GR1-4001. Serial 1177. Controller is FSIP part FS42L500PNVS, serial SSCS-M54003-2. I used Manual 101935402, chapter 19 to troubleshoot. Item 5, tests 3 F&R switch and 6 controller to motor. Passed every test. Any help is greatly appreciated. Additionally, if anyone has a part numbers for the service and maintenance manual for 2005 carryall 2's and 6's I'd be much obliged. Have a great weekend.

[NoleFan4Ever]

I do not know your motor/controller combination but is this a sepex or series cart? (Rocker switch or FNR handle)

And CTD or Raystar or someone close usually has access to manuals.

[Raystar57]

I don't have or can find the wiring diagram for this.
This is a series motor and controller.
This could be a F/R switch or a micro switch issue.
Since I can't find the schematic I am in the dark.
CTD may have something.

I see info on the FSIP site for FS42L500NNVS
but not for FS42L500PNVS

Not sure what that difference is.

[FRC Dave]

It is a series cart. I am trying some things Dave Hicks suggested but so far no go. As to the NNVS vs the PNVS on the FSIP controller. the NNVS is for EZ-GO and does not have an A2 terminal. I changed out the controller with another from FSIP because the 270 ohm resistor was burning up but still no go. I will try again on Monday.

[lockman1]

Attached is an 04-05 Carryall Illustrated Parts List,
Pages 14-10 & 14-11 have your wiring diagram.
BUT... no part numbers for what your looking for, it only has part numbers for the wire harnesses.
(As do the 03, 06, and 08 parts lists also)

I gather this won't help you very much, but at least it's something!

[Sergio]

You did not mention if the Solenoid was clicking when you put the FNR in reverse.

If the Solenoid is clicking, I would suspect the 1/2 speed resistor in the throttle power.

Remove the Green, white and black wires from micro-switch #3.

Tape the black wire as You will not use it.

Connect the Green and the White wires together, that will give you full throttle in Forward and Reverse.

[Raystar57]

Originally Posted by FRC Dave

It is a series cart. I am trying some things Dave Hicks suggested but so far no go. As to the NNVS vs the PNVS on the FSIP controller. the NNVS is for EZ-GO and does not have an A2 terminal. I changed out the controller with another from FSIP because the 270 ohm resistor was burning up but still no go. I will try again on Monday.

Dave, thanks for that info on the PNVS and NNVS!
Thanks lockman1, I can see in the dark now!
Sergio, that is great! Resistor could be open or micro-switch has a problem.

I am concerned about the 270ohm resistor burning up...
This would indicate that the solenoid main contacts are not making a good connection when engaged
and high current demand is flowing through 270ohm precharge resistor.
This could indicate a bad solenoid.

[FRC Dave]

Originally Posted by lockman1

Attached is an 04-05 Carryall Illustrated Parts List,
Pages 14-10 & 14-11 have your wiring diagram.
BUT... no part numbers for what your looking for, it only has part numbers for the wire harnesses.
(As do the 03, 06, and 08 parts lists also)

I gather this won't help you very much, but at least it's something!

Thanks for the download. One thing I do have is parts manuals. I have very limited service manuals.

[FRC Dave]

Originally Posted by Sergio

You did not mention if the Solenoid was clicking when you put the FNR in reverse.

If the Solenoid is clicking, I would suspect the 1/2 speed resistor in the throttle power.

Remove the Green, white and black wires from micro-switch #3.

Tape the black wire as You will not use it.

Connect the Green and the White wires together, that will give you full throttle in Forward and Reverse.

Sorry for the delayed reply. I am the only Club Car, EZ-GO, Cushman, Taylor-Dunn mechanic where I work. I tried what you suggested and all I got was the motor making a high pitched noise in forward like it wanted to go an do nothing in reverse. I noticed the batteries not holding a charge like I thought they should. I had previously checked the cells with a hydrometer and they are not charging up even though the charger is working. They are 3 years old so they are being replaced. Then I will start over.

[FRC Dave]

Originally Posted by Raystar57

Dave, thanks for that info on the PNVS and NNVS!
Thanks lockman1, I can see in the dark now!
Sergio, that is great! Resistor could be open or micro-switch has a problem.

I am concerned about the 270ohm resistor burning up...
This would indicate that the solenoid main contacts are not making a good connection when engaged
and high current demand is flowing through 270ohm precharge resistor.
This could indicate a bad solenoid.

Thanks for the reply. I will install a known good solenoid when I get new batteries in and see what happens. One thing I did notice is that when I changed the controller like Tahoe Dawg suggested, the resistor is no longer overheating. I have no say so in parts I receive. I order from the Club Car manual and I get what our supply gets from bidders. (I work on a military base). I will keep all posted when repairs work to let others know what repair procedures work to solve the issue.