2002 Club Car power issue

[BobbyT]

Here is the other picture I was able to take.

[Sergio]

Make sure the controller is providing the proper power to the speed sensor.

Set Your meter to 20v DC.

Disconnect the 3-pin connector for the speed sensor.

Take the measurements on the harness side connector.

From Black/White (negative probe) to Red (positive probe) : +15v
From Black/White (negative probe) to Green (positive probe) : +5v

If those readings are correct, the sensor has the proper power it needs to work.

You then need to check if the sensor is actually working, which means the issue is with the controller.

Plug the speed sensor 3-pin connector back.

If You have a wire piercing probe, pierce the Green wire (positive probe).

If You don't have a wire piercing probe, You will need to connect the positive probe to Controller pin #14.

The negative probe will go on pack negative in either case.

As You slightly move the tire, the equivalent of a 1 hour clock dial movement of the tire will generate 8 transitions, the meter should go from 0v to 5v as the speed sensor detects the magnet poles.

If the meter does not change from 5v to 0v, the speed sensor is either bad or it cannot detect the magnet poles.

If the meter is changing from 5v to 0v and the controller is not beeping and powering the motor field coil, the controller circuit for the speed sensor is bad.

[BobbyT]

Sergio, Thanks for the great troubleshooting info. Here is what I found. With sensor disconnected the run/tow switch in run and the key on I had 15.7v on the red wire and 5.01v on the green. I then reconnected the sensor and connected the meter black lead the battery pack negative post and pierced the green wire as instructed. the meter was reading5.67v and I then rotated the tire the slight amount you said with NO meter fluctuation at all. So with those results and if I understand you correctly I have either a bad sensor or bad magnate. Is that correct ? Thanks again for all your help. You guys on this forum are great !!!!!

[Sergio]

That is good, at least the controller is providing the correct power the sensor needs to operate.

If You have a fridge magnet, You can try to use it to trigger the speed sensor.

One thing to keep in mind is that the polarity of the magnet as detected by the sensor has to change for it to change the output on the Green wire from 5v to 0v.

Once the sensor detects a different polarity, it will "latch" or keep that new state even after you remove the magnet and will not change it again until it detects the opposite polarity.

A strong magnet will be detected even from the backside of the sensor, so You can try placing a magnet in different orientations (polarity) touching the sensor to see if it changes states (from 5v to 0v).

Although the picture You posted looks like the magnet was in the correct place, so You may have another bad sensor.

[BobbyT]

I was told the the magnet should be flush with the end or the armature shaft. The one I have is pressed on a bit further than approx 1/16 or so. Could that make the difference ? It's very obvious that you are much more knowledgeable about this thing than I am so would you do any further testing or go ahead and get another speed sensor and magnet ? At this point my frustration level is pretty high.

[TahoeDawgZ71]

Originally Posted by BobbyT

I was told the the magnet should be flush with the end or the armature shaft. The one I have is pressed on a bit further than approx 1/16 or so. Could that make the difference ? It's very obvious that you are much more knowledgeable about this thing than I am so would you do any further testing or go ahead and get another speed sensor and magnet ? At this point my frustration level is pretty high.

Your magnet appears to be installed properly. It's hard to say for sure. You could install a high speed magnet in an attempt to fix your problem, or you could order a replacement sensor. Your controller is obviously working properly but there's a problem with the sensor or the magnet.

[BobbyT]

Thanks for the advice David. Would the high speed magnet help increase the top end speed of my cart ? If I replace the sensor and magnet would I have to do any other mods to make them work properly ? My feeling is with the help of some really knowledgeable folks on this forum that have been very helpful if I replace both components I am almost assured that my issue will be behind me.

[Sergio]

Those sensors don't have a real big "gap" tolerance, but I would assume the design would accommodate for that kind of variance, meaning your gap is not excessive.

My experience is with the ADC motor and sensors and that particular design is not affected by magnet positioning.

The speed magnet will definitely increase the speed of your IQ cart and David sells the known good quality sensors.

[TahoeDawgZ71]

Yes the magnet will speed your cart up, but only with a good quality sensor. As Sergio said, we have them both.

[BobbyT]

Thanks Sergio, After all the trials and tribulations I have been through I am going just bite the bullet and replace both components. I will post the results. Many thanks to all have given this newbie cart owner so much of your time