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Unread 10-05-2016, 03:43 PM   #1
Not Yet Wild
 
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Default Having trouble understanding 1987 club car

Hello all, I have having a hard time wrapping my head around the current flow on a 1987 Club Car with 5 solenoids and the resistors. I understand that the resistors inline will reduce the voltage to the motor, but I am having a hard time understanding how these resistors are bypassed. Could anyone help me out with this? Thanks
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Unread 10-05-2016, 05:23 PM   #2
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Default Re: Having trouble understanding 1987 club car

This is a combination of previous posts about the operation of the 5 solenoid system:

As the pedal is pressed, 5 micro-switches inside the control box (aka: speed box, throttle box) close in sequence.
micro-switch #1 triggers the master solenoid closest the driver side. The master solenoid connects the motor to the buss-bar, but no voltage exists at the buss-bar at this time so the cart does not move.

micro-switch #2 triggers the next solenoid closest to the master, the cart moves at it's lowest speed since power passes through ALL of the the resistor coils before reaching the buss-bar (max resistance).

micro-switch #3 triggers the next solenoid in line allowing power to reach the buss-bar through one less resistor coil. Less resistance allows more current to the motor.

micro-switch #4 allows current to go through two less resistor coils resulting in more power going to the motor and more speed is produced.

micro-switch #5 allows current to flow directly from the FNR to the buss-bar to the motor without the use of any a resistor coils. This direct connection produces the max power and speed.

Additionally you need to understand these solenoids are 36v continuous duty golf cart specific! No automotive substitutes will work for long.

Each solenoid has 2 small posts for activation. It takes a + and - at the small posts to trigger the solenoid to close the contacts between the large posts.
The - (negative) side of the solenoids activation feed is daisy chained together... all solenoids share a common source or wire from the F&R ms by way of the key switch (negative).

Like this battery B- > key-switch > F&R micro-switch > all solenoids.

The + side of the circuit comes from the 5 micro-switches in the little silver box at the end of the gas pedal linkage which are activated sequentially by the slide inside the "control box" discussed above.
The reverse buzzer is always connected to the +36v side, when the FNR is on reverse, the other side of the reverse buzzer is connected to B- by the way of the Motor Stator coil.
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Unread 10-05-2016, 06:00 PM   #3
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Default Re: Having trouble understanding 1987 club car

Thank You very much. I don't know why that was puzzling me. It all makes since now. I did search the forum but didn't really find the answer. Thanks
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Unread 10-05-2016, 06:02 PM   #4
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Default Re: Having trouble understanding 1987 club car

It's that time of year again! LOL

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Unread 10-08-2016, 07:49 AM   #5
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Default Re: Having trouble understanding 1987 club car

So voltage is present on the motor as soon as the master solenoid is activated, only the current is reduced by the resistance of the coils. Correct? And, the lower current is what controls the speed? Thanks.
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Unread 10-08-2016, 08:37 AM   #6
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Default Re: Having trouble understanding 1987 club car

Quote:
Originally Posted by Drivembig View Post
So voltage is present on the motor as soon as the master solenoid is activated, only the current is reduced by the resistance of the coils. Correct? And, the lower current is what controls the speed? Thanks.
No, only when the first speed solenoid is activated. 36 volts is being closed, but due to all the resistors that voltage is being reduced so that the cart accelerates smoothly.
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