DS series lacking power F&R

82 gt

Im new to golf carts and this site....i apologize in advance

From what i have gathered, i have a 86 DS 36v cart, ID #A8627101181 and it has been a problem child from the get-go

Latest trouble consisted of a solenoid sticking "on" (im assuming) and it was moving regardless of key and pedal. Well, in the process of loading it into my truck to take it home and work on it, the SOB caught fire at the F-R switch which i quickly extinguished.

Replaced the following at this time:

-F-R switch
-(5) solenoids (used Club Car 36v solenoids)
-Strap that ties all solenoids together (aluminum?)
-(5) microswitches (replaced with Eaton units)
-Accelerator linkage rod

**Batteries all replaced in August. (6) Super Start golf cart batteries installed (75a)**


Now the cart will hardly move. Forward or reverse....doesnt matter. Acts like a dead battery pack. All water levels in the batteries are normal and it has 39.7v fresh off charge. I go to back it up, and have to push it back. I go forward and it slowly creeps along and gradually gains some speed, but nothing like normal. If i depress the pedal fully, it cuts out entirely as if it shut off, but if you let off the pedal and feather it, it will go again.

I moved it (pushed it) back 10' and drove it forward 10' and the voltage dropped to 37.6v

I monitored the voltage while in reverse and it dropped to 36.6

I monitored the voltage while moving forward and it dropped to 35.9

The big wires (3 of them) to the solenoid and motor all tested around .10 ohms on a 200ohm setting.

I tested the batteries this morning with a Auto Meter tester and all tested good


All wiring i did mirrored what was there existing and diagrams i found online (which most came from this site, lol) and it seems like I have wired it correctly, but hey, Ive been known to make a mistake or two.


Im just stumped...flat out stumped. Hopefully someone can steer me in the right direction!


**Well, ive tried twice to post pics and this site isnt letting me. Apparently I have to be a member for 7 days before i can post pics**

BGW

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mrgolf

Can you post photos on photo bucket and post the link here. I would like to see the battery hook up.

82 gt

Thats what i was trying and the site refuses to let me. I have to be a member for more than 7 days. Guess im S.O.L.

I can email them to ya if you dont mind posting them for me...dunno if thats frowned upon or not

mrgolf

It sounds to me like you have voltage and no amperage. Never known of anyone using those batteries. Lots of times the guys who do most of the helping on this forum can spot wires in the wrong place, and lots of errors from looking at photos, that's why I ask if you could post some photos. Hang in there we will get this figured out with enough information from you and have you do some testing.

CCFanatic

82 gt

Yessir, thats the battery

82 gt

Hey...the picture issue has been resolved!

CCFanatic

The cables in there look like they've seen better days. Would be best to put a whole new set it. That is more than likely a big contributor to your issue. I'm especially not fond of the washer on the one F-R switch contact

mrgolf

Are all the solenoids working correctly. From what I have learned from reading this site, they control the speed, they operate one at a time as you press the pedal, each gives you more speed and power. If those are not connected correctly and are not working that may be your problem.

We have guys on this site that know those carts very well, all I know about them is what I've learned on this site.

I do agree, those cables would have to go if we're my cart, but that's me.

CCFanatic

Just noticed something in the motor picture. The two innermost studs on the motor, in the posted picture, are those bolts threading into the motor rather than studs?