96 club car won't run

tfritch72 · 08-08-2015, 11:46 AM

I have a 96 club car, serial #A9642-536207. I broke it out of the inlaws shed last summer and installed new batteries. Ended up having to buy a new charger as the obc was bad. All was good until about a month ago. Cart would just quit as if it had been turned off. Did this a few times and now won't run at all. Now I turn on the key and hear the solenoid click twice just like I understand it is supposed to. I push the accelerator, the soleniod clicks, and there is a humming noise coming from the motor but nothing happens. I am confused on a couple matters. First of all the solenoid. As I understand it the solenoid is basically a switch. To me that means it should have a open and closed position. Mine appears to be closed all the time when the key is on, meaning I have no real measureable voltage difference between the to big posts. I also have full voltage at the controller when the key is on, is this normal? My second concern is the noise from the motor. It hums and I can feel something happen by touch when the accelerator is pushed. Any help would be appreciated. From the reading I have done these carts are quite the piece of work. Thanks. Terry

08-08-2015, 01:29 PM

wow .....
ok solenoid first ... it should not click twice
yes it's just a switch, open no power, closed power

solenoid test

Quote:

Disconnect the negative battery cable from the battery. remove all wires, restorer , and diode from solenoid
test 1
Connect an volt meter, set on continuity, place on the two large terminal studs. The meter should indicate no continuity, Replace the solenoid if continuity is present.
test 2
Using jumper wires attach from main positive and main negative of battery pack to the two small solenoid studs, polarity is not important. You should hear a click as the solenoid engages, and the meter should indicate continuity on the two large terminals. Replace the solenoid if continuity is not present.
if solenoid clicks rapidly solenoid is bad

motor .... try testing it

motor test

WARNING you don't want to make a big spark anywhere near the battery.

jumper cables may be used
black clip on battery negative,
red clip on motor A1 post, tap the other ends together

tfritch72 · 08-08-2015, 03:40 PM

Ok...the solenoid appears to be ok and the motor runs off of my lawn mower battery, very slowly, but it does run. the only thing left in the mix is the controller??? it must be at the root of my problem I'm guessing.

08-08-2015, 03:46 PM

yep ... i think this test should work for you
again test with wheels off the ground
controller by-pass

Quote:

You can bypass the controller for testing only.

Jack the rear tires off the ground and put the cart on jack stands. Jump B- and M- at the controller to bypass the controller.
Make the final connection away from the controller(connect 2 jumper wires to controller and touch them together )
it's going to run at wide open throttle. If it runs with the jumper I'd say the controller is bad.Don't let the cart run at full speed with the rear tires off the ground..

tfritch72 · 08-08-2015, 04:16 PM

hit a little snag...I don't have a B- or a M- on my controller. I have a p(power in), n(main neutral to battery bank), an A1, an A2, a F1 and a F2, all of which hook to their corresponding lugs on the motor.

08-08-2015, 04:47 PM

yes you do

96 DS controller

tfritch72 · 08-08-2015, 04:52 PM

ok...i have found nothing that looks like this. Where would it be hiding?

08-08-2015, 05:12 PM

wait ... do you have a 36v or 48v cart ?

tfritch72 · 08-08-2015, 05:23 PM

48...mine looks more like a short fat T. i have been looking through schematics and have found nothing that matches mine.

08-08-2015, 05:25 PM

this one ?

08-08-2015, 11:46 AM	#1
tfritch72 Not Yet Wild Join Date: Aug 2015 Posts: 18	96 club car won't run I have a 96 club car, serial #A9642-536207. I broke it out of the inlaws shed last summer and installed new batteries. Ended up having to buy a new charger as the obc was bad. All was good until about a month ago. Cart would just quit as if it had been turned off. Did this a few times and now won't run at all. Now I turn on the key and hear the solenoid click twice just like I understand it is supposed to. I push the accelerator, the soleniod clicks, and there is a humming noise coming from the motor but nothing happens. I am confused on a couple matters. First of all the solenoid. As I understand it the solenoid is basically a switch. To me that means it should have a open and closed position. Mine appears to be closed all the time when the key is on, meaning I have no real measureable voltage difference between the to big posts. I also have full voltage at the controller when the key is on, is this normal? My second concern is the noise from the motor. It hums and I can feel something happen by touch when the accelerator is pushed. Any help would be appreciated. From the reading I have done these carts are quite the piece of work. Thanks. Terry
tfritch72 Not Yet Wild Join Date: Aug 2015 Posts: 18

08-08-2015, 03:40 PM	#3
tfritch72 Not Yet Wild Join Date: Aug 2015 Posts: 18	Re: 96 club car won't run Ok...the solenoid appears to be ok and the motor runs off of my lawn mower battery, very slowly, but it does run. the only thing left in the mix is the controller??? it must be at the root of my problem I'm guessing.
tfritch72 Not Yet Wild Join Date: Aug 2015 Posts: 18

08-08-2015, 04:16 PM	#5
tfritch72 Not Yet Wild Join Date: Aug 2015 Posts: 18	Re: 96 club car won't run hit a little snag...I don't have a B- or a M- on my controller. I have a p(power in), n(main neutral to battery bank), an A1, an A2, a F1 and a F2, all of which hook to their corresponding lugs on the motor.
tfritch72 Not Yet Wild Join Date: Aug 2015 Posts: 18

08-08-2015, 04:47 PM	#6
crash test dummy Guest Posts: n/a	Re: 96 club car won't run yes you do 96 DS controller
crash test dummy Guest Posts: n/a

08-08-2015, 04:52 PM	#7
tfritch72 Not Yet Wild Join Date: Aug 2015 Posts: 18	Re: 96 club car won't run ok...i have found nothing that looks like this. Where would it be hiding?
tfritch72 Not Yet Wild Join Date: Aug 2015 Posts: 18

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08-08-2015, 05:12 PM	#8
crash test dummy Guest Posts: n/a	Re: 96 club car won't run wait ... do you have a 36v or 48v cart ?
crash test dummy Guest Posts: n/a

08-08-2015, 05:23 PM	#9
tfritch72 Not Yet Wild Join Date: Aug 2015 Posts: 18	Re: 96 club car won't run 48...mine looks more like a short fat T. i have been looking through schematics and have found nothing that matches mine.
tfritch72 Not Yet Wild Join Date: Aug 2015 Posts: 18

08-08-2015, 05:25 PM	#10
crash test dummy Guest Posts: n/a	Re: 96 club car won't run this one ?
crash test dummy Guest Posts: n/a