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Unread 10-27-2014, 12:00 AM   #1
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Default 1995 48v DS no solenoid click & no movement intermittently

I have a 1995, 48 volt model DS, serial number is A9547-474966.

I have had this issue happen for a second or two once or twice before, but this weekend it did it and wouldn't start again so I had to leave it in the field and walk to my hunting blind.

The cart worked fine from the time I jumped on it in the dark for the first five minutes or so and 300 - 400 yards. I slowed to drive through a small draw and when I went to press the pedal to climb the ten or so feet up the other side it was just dead. The solenoid didn't click any more and there was no movement. I tried rocking the cart, turning the key on and off, moving the lever from F to R and many combinations of these acts. The whole time my lights remained on, so I knew it wasn't a full electrical failure. After a few minutes of messing with it I left it there and walked to my hunting blind. The cart was left in a prime travel area though and I think it messed up my morning hunt.

So I walked back to it several hours later and it was still dead.

I proceeded to walk everywhere else I needed to and did some more work around the property. About 3 PM, a good nine hours after it died, I drove over to it in my truck with intentions of towing it back to camp. Well, I jumped in it and sure enough it worked just fine. I drove it straight back to camp and I the shed. I plugged in the charger and it kicked on like normal.


So since the solenoid did not click, what do I need to be looking at for loose wires or replacement micro switches? I searched for about an hour and most of the threads I found do not deal with carts that do not click, but rather a click but no movement.

The cart is seven hours away at the camp now and I would like to have some things to try next weekend when I return. If I need to order some parts, I want to get them on order Monday so hopefully they will arrive by Friday.


Upgraded this year were all of my battery cables with a 2 gauge kit from ScottyB. I also got a new, heavy duty F&R switch at the same time. I am still running the original Curtis controller for the time being.

Thanks,
Tim
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Unread 10-27-2014, 12:50 AM   #2
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Default Re: 1995 48v DS no solenoid click & no movement intermittently

Try this
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File Type: jpg 95cc solenoid activation.jpg (114.7 KB, 0 views)
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Unread 11-02-2014, 11:14 AM   #3
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Default Re: 1995 48v DS no solenoid click & no movement intermittently

So I'm sitting in my dead cart on the far end of the ranch posting this.

I am getting positive where Scotty said I should but no negative on the small post on the solenoid where the yellow wire is connected. What does this mean is wrong? It appears that the yellow wire is coming out of the OBC. The cart charges fine. Can I put a jumper from the pack negative to this small post to get going again?

Thanks for the assistance.

Tim
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Unread 11-02-2014, 11:26 AM   #4
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Default Re: 1995 48v DS no solenoid click & no movement intermittently

Quote:
Originally Posted by TimOub007 View Post
So I'm sitting in my dead cart on the far end of the ranch posting this.

I am getting positive where Scotty said I should but no negative on the small post on the solenoid where the yellow wire is connected. What does this mean is wrong? It appears that the yellow wire is coming out of the OBC. The cart charges fine. Can I put a jumper from the pack negative to this small post to get going again?

Thanks for the assistance.

Tim
Yes, you got it!
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Unread 11-02-2014, 09:37 PM   #5
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Default Re: 1995 48v DS no solenoid click & no movement intermittently

Thank you Sergio.
I didn't have any connections to make up a little wire but got it back to camp. Plugged it in to the charger and it kicked on like normal. The pedal was still dead at that point.

So if I can just jumper over from the pack negative to this small post on the solenoid and it gets it moving again, what does this mean? What is broken or wrong? Is it the OBC and if so is this the beginning of the end for it?

As I have read on hear before, I understand that the OBC is just to control the charger. Is that correct? And this yellow wire is just a safety measure to prevent someone from driving off with the charger still plugged in. Is that correct?

My wife is to the point of wanting something new but I know this is something very minor. She just wants something reliable when she is out on the ranch with our girls. If I/we decide to go with a new ride I'm leaning heavily towards the Polaris Ranger EV. The only thing my Club Car won't do well is carry a road feeder. It weighs at least 100 pounds when full. I broke the front of the frame last year from the weight. Put a bolt on 2" receiver hitch on the rear seat foot rest and nearly broke that off this year. I need some way to mount a 2" receiver hitch to the frame. This is standard on the Ranger, but comes with a hefty price tag. Thoughts?

Oh, and the Ranger will ride a lot smoother than my DS with a simple lift.

Thanks for all the great info,
T
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Unread 11-04-2014, 12:53 PM   #6
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Default Re: 1995 48v DS no solenoid click & no movement intermittently

Throwing this back up top hoping to get some answers to the last questions I posted.

So if I can just jumper over from the pack negative to this small post on the solenoid and it gets it moving again, what does this mean? What is broken or wrong? Is it the OBC and if so is this the beginning of the end for it?

As I have read on hear before, I understand that the OBC is just to control the charger. Is that correct? And this yellow wire is just a safety measure to prevent someone from driving off with the charger still plugged in. Is that correct?

Thank you,
Tim
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Unread 11-04-2014, 01:21 PM   #7
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Default Re: 1995 48v DS no solenoid click & no movement intermittently

Correct, that is basically a safety so folks don't drive off while the cart is charging

As long as the OBC is controlling the charger correctly, I would just disconnect that yellow wire and tape it off so not to accidentally short anywhere.

Run a separate 18ga wire from the B- on the controller to that post on the solenoid.

I would also check the diode on your main solenoid, a failure of that diode is most likely the cause of the OBC lockout circuit going bad.
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Unread 11-17-2014, 03:14 PM   #8
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Default Re: 1995 48v DS no solenoid click & no movement intermittently

Well, I spent a few days out at my place late last week and the first thing I did was add a jumper wire from the pack negative to the spot that the small, yellow wire is connected to the solenoid (top right). This did absolutely nothing. The machine didn't move at all for me this weekend. Had to drive the truck around, which wasn't all that bad considering it was in the 20's Friday morning. It was dry so I had no issues and left no ruts either.

I'll be back out there this weekend and probably going to bring it home with me on Sunday. Any other insight?

Thank you,
Tim
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