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Unread 04-29-2015, 05:28 PM   #1
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Default 96 48 volt ds, shuttering and solenoid clicking

Working on a 96 48 volt ds it looks like. First off someone has put 4 12 volt marine batteries in it. When you turn the key on and put it in forward or reverse the solenoid continually clicks and the car shutters when you try to take off.
I put my volt meter across the pack and it shows 50 volts and i held the brake and hit the gas pedal to load the pack and voltage dropped to 46.8 volts. I know that a bad battery is usually the cause of the shuttering but the solenoid just continually to click, i am not sure what would cause that. Checked all the wiring and it all seems to be correct.

Thanks Tim
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Unread 04-29-2015, 05:48 PM   #2
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Default Re: 96 48 volt ds, shuttering and solenoid clicking

This cart probably has the dreaded pot box throttle. To verify, look for a little black box directly under the GO pedal. If there's not one, look for a black pie shaped box in between the batteries under the seat. That would be a V-glide.
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Unread 04-29-2015, 05:49 PM   #3
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Default Re: 96 48 volt ds, shuttering and solenoid clicking

A poor connection somewhere in the high amperage side of the system can give the same result.
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Unread 04-30-2015, 10:21 AM   #4
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Default Re: 96 48 volt ds, shuttering and solenoid clicking

Its not a v-glide setup. What do you mean by the high amperage side? I did find one bad spade connection and fixed that and it has a new solenoid on it.
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Unread 04-30-2015, 10:24 AM   #5
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Default Re: 96 48 volt ds, shuttering and solenoid clicking

The high amperage side is all the thick heavy gauge cables. Check them all by giving a slight tug to each of them...
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Unread 05-29-2015, 11:26 AM   #6
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Default Re: 96 48 volt ds, shuttering and solenoid clicking

Ok guys, sorry for it being a while responding but I think i found the problem. I'm pretty sure the OBC is bad. I jumpered the recepticle side of the charger to negative on battery pack and I hear the relay in charger kick on. My next question is, does this disable the charger from turning off so now you have to unplug the charger?
And for the solenoid continuously clicking, i'm pretty sure the OBC is causing that because the ground side of the solenoid is not grounded like it should. I took the small yellow wire from solenoid that is ground side going to the obc and disconnected it from the obc. I ran it straight to the negative on the battery pack. Now when you turn the key on and put it in forward you hear the solenoid click once and car goes and no shuttering or anything. My big question is, is there any negatives to leaving it all hooked up this way and bypassing the OBC?
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Unread 05-29-2015, 12:24 PM   #7
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Smile Re: 96 48 volt ds, shuttering and solenoid clicking

Do you have a shift lever and no run/tow switch?
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Unread 06-01-2015, 01:04 PM   #8
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Default Re: 96 48 volt ds, shuttering and solenoid clicking

Yes. Series car and no run/tow switch.
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