electrical problems installing digital volt guage

[lvandyke]

thanks JohnnieB for the flow thru diagram of controller- helps to see the path for troubleshooting. I have pack voltage at reed switch to pin4 on J1. looks like I need to put in run mode to get voltage out Pin9 to +key switch w/ White/Yel wire. if I cant get voltage there I'll re-check the wiring for breaks, but to have it go out standing still leads me back to originally installing DVM w/ run/maintenance switch in run.

[JohnnieB]

I suspect you damaged the wires or connectors associated with the keyswitch or F/R switch while removing or replacing the dash mounted plated, so it might not have mattered if it was in Tow or Run while you were working on it, but in the future always put it in Tow when you mess with any of the wiring anywhere on cart.

It might be simply a loose connection, one of the five on those two switches.

The voltage from the reed switch ends up one the yellow wire on the solenoid. You've got it on J1 Pin-4, so the next place is J1 Pin-1, then either J1 Pin-2 or pin 3 (Reverse and Forward respectively) and then to J1 Pin-9. Next is J1 Pin-8 and finally J1 Pin-7 to solenoid.

Basically, the voltage path from the battery positive terminal to one side of the solenoid coil is a single piece of wire with a lot of kinks in it.

[lvandyke]

thanks for the flow explanation. makes it easier to find the breakdown. but I will need to put in run to check voltage downstream from reed switch, right?

[JohnnieB]

Originally Posted by lvandyke

thanks for the flow explanation. makes it easier to find the breakdown. but I will need to put in run to check voltage downstream from reed switch, right?

Yes.

[lvandyke]

finally got some voltage numbers to troubleshoot electrical disconnect from prior installation of digital VM.
24 hr+ after charging, I have pack V 37.3- following that downstream I have:
J1 pin4 37.3
pin1 .6
pin2 0
pin3 .6
pin4 37.3
pin5 37.3
pin6thru8 0
pin9 .6
pin10 36.9

so-pack voltage to Ji pin4 but nothing out to F/R and Key switch.
Solenoid has 0 at yellow, 37.3 at red, 36.7 at black and 0 at blue.

on Controller A1=36.7
B- =0
B+ =36.7
Did I short something in stock original Controller?

[JohnnieB]

The voltage on J1 Pin-4 goes through the Run/Tow switch before it gets to J1 Pin-1.

Check the voltages on J3.

[lvandyke]

continuing the troubleshooting electrical break- checking the run/tow J3 pins as suggested: "The voltage on J1 Pin-4 goes through the Run/Tow switch before it gets to J1 Pin-1. Check the voltages on J3."

pack voltage was 37.7 at start of check
in Tow mode: J3 run mode J3
Pin 1 red= 37.7 37.7
pin2 red/y=28.9 37.7
pin3 red/w=37.7 37.7
pin4 org/r=0 37.7


I see that pin4 goes thru something called REG in controller before going to J1 pin1. beyond that I am lost.

thank for any guidance, hoping to not replace controller but time will see.

[envoy98]

Following as this is almost identical to the issues I am also having. I am/was resigned to ordering a rebuilt controller. I did try a new F/R switch and no help so you can probably check that off your list.


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[lvandyke]

well, JohnnyB is a wiz and I'm sure he and the rest of this group can guide us thru.

[envoy98]

I promise not to hijack, I’ll just be a fly on the wall testing the same things.


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