2011 Carryall Help Needed

[PMD3454]

SN is QT1129. Photo of solenoid and controller nameplate below. Red and yellow wires leading off to right side of solenoid photo go to hour meter. Let me know if this isn't what you were looking for and I'll get more.

[PMD3454]

Sorry about the upside down photo. Don't know why it did that. Will go get better photos and send in a few minutes.

[PMD3454]

additional photos

[PMD3454]

Also, the Illustrated Parts document for a 2011 Carryall, page 14-4 shows the 24 pin controller connector configuration. Pin 8 isn't labeled, but it had a green wire and based on the diagram and info from other 16 pin diagrams, I assumed that to be the throttle switch. I could get 48V on and off on that pin by activating the pedal. I tried to upload that doc but the file is just a little larger than what's allowed. Will try to extract those pages tomorrow and forward them.

[Fairtax4me]

I did find a diagram for this, and trying to make some sense of a couple things on it, I'm not sure the function of the extra relay, which appears to just bridge the solenoid posts. The controller handles the coil function for that, so I'm guessing it has something to do with roll away or regen brake function. Not sure that has anything to do with the issue though.

Right so, the 4 pin small connector is the data connector, which if you have a Curtis scanner you could hook it to there to communicate with the controller.
The 6 pin connector with three wires is just for the motor speed sensor input. It also appears to be a negative maybe for some kind of warning lamp. None of those are going to affect whether the cart works or not.

Given what you've tested so far in the post above, it sounds to me like everything needed for the cart to work is getting to the controller, and the controller is dead.
On the White wire pin 13 you should be getting about 5v out of the controller to provide power for the MCOR.
The controller is also supposed to handle solenoid activation, and the fact it's not activating the solenoid, even though it seems to have all of the proper inputs.

One thing I'm not quite sure of if you said nothing was getting power until you jumped the solenoid, there is a circuit breaker in the diagram although I can't see it in the pics. The circuit breaker appears to be the power source for the Tow/run switch and thus everything else, so I would check that to see if it is supplying 48v to the electrical system.

OBC stuff, you said the charger doesn't come on when plugged into the cart, and since the OBC does put the controller in charge interlock it's worth making sure the OBC does detect that the charger has been plugged in.
Check that the Red wire from the charge receptacle is connected to the battery pack main positive post, and that you have full pack voltage present at the red wire pin in the receptacle with black meter lead on pack negative. If you check voltage from the red wire pin to the Black wire pin in the receptacle, you should see a drop of maybe 10-15v, so you should see anywhere from 35-40v across those two. If the voltage is outside of that range that would indicate the OBC is damaged.

Check the main charge fuse on the receptacle, and check the fuse in the yellow fuse holder on the grey wire. If those check out OK, then try plugging the charger into the receptacle and jumper the grey wire from receptacle to the pack negative and see if the charger turns on. If it does, then that would show the OBC is faulty. If it does not turn on, the relay in the charger or possibly wiring in the charger is faulty, but we won't know if the OBC is bad until we know that the charger definitely works.

[Fairtax4me]

Also should add, another possible test of the controller is to check for the 5v output to the motor speed sensor. I don’t remember off hand which wire it is.
The controller uses the speed sensor to determine that the cart is moving and activate the roll away brake feature. This is enabled anytime the tow run switch is in Run. So assuming the controller gets 48v on the Tow/Run input, it should be applying 5v out to the speed sensor.
I’m not sure how that feature is affected if the OBC interlock is active, but if the OBC is providing 48v on the Lt Blue wire to the controller then the interlock is not enabled, and the controller should be giving throttle and speed sensor 5v outputs.

[PMD3454]

Did three posts last night and all three aren't here this morning??

First 6 digits of SN are QT1129

Sorry about the one being upside down. I couldn't get it to post flipped upright. On the solenoid photo the two wires leading up and to the right go to the hour meter.

Also, I used the details in the illustrated parts list for the 2009-2001 Carryall Turf 2 to sort through the pin testing. I tried to post here but file size is too large. Page 14-4 shows the details of the 24 pin connector. pin 8 isn't labeled but it had a green wire. I tested that at 48v and confirmed it as throttle switch by activating the pedal and getting 48V off and on.

[PMD3454]

Please let me know if you need more or different photos. Thank you for helping me through this.

[PMD3454]

I've posted requested info last night and again this morning and it gets removed. Am I breaking rules or doing something that isn't allowed?

[PMD3454]

Thank you for all of the input. Can't work on cart tonight but will get into it on Thursday and provide feedback here.