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Unread 05-24-2009, 09:05 PM   #1
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Default 82 CC DS Solenoid Check

I've scoped out several treads and haven't quite hit on my specifics, although very helpfull. Installed the new batteries and studied the soleniod situation. The first one clicks, the second one clicks( no motion). The third one clicks (still no motion). The fourth one clicks ( we got MOTION). The fifth one clicks and does increase speed! Do I need soleniods or do I look else where? Thanks.
I live and play outdoors with my Big Dogs
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Unread 05-25-2009, 09:50 AM   #2
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Default Re: 82 CC DS Solenoid Check

I hope that this will not seem overwhelming but needed to help find your problem.
When the 4th solenoid clicks you stated that you had motion? Do you mean that the cart took off or that you only had it move slightly or what? When the 5th one clicks are you at top speed or have a little more movement? The resistors act as speed control but once you get to top speed ( 5th Solenoid ) they are out of the circuit.
The FIRST Solenoid only adds power to system so no movement seen, second solenoid should have you moving but slowly, third should have you at about a slow walking pace, fourth should be near top speed, fifth should have you running at about 10-12 mph. Solenoids can click and still not give voltage to motor in some cases. Will get to that later on.
I know that you stated that you replaced the batterys with new ones, but did you double checked for correct connections on new batterys and have you charged them up fully? Installation can be a very confusing thing to do and often accounts for NONE RUNNING CONDITION AFTER installation. What was the conditions BEFORE you replaced batterys? Would the cart run but poorly or not at all? As I have found bad batterys before even when NEW I would do a the following. Do a battery test on your pack. Do you have a digital volt meter or a hydrometer with temperature correction on the side? If you have a meter test each battery and write down readings for us.
( Example )
#1 battery reads 6.0 volts, # 2 battery reads 5.8 volts, TOTAL pack voltage 36 volts
If you have a hydrometer check each cell in your batterys and write down
( Example )
# 1 battery cell 1-1.270, cell 2-1.100, Cell 3- 1.225.
This will tell us if you have battery and or control problems. It sounds as if you may be having solenoid problems but lets start with battery condition and go from there. Then its on to connection conditions on battery pack and controls. NEVER ASSUME that batterys are good just because they are new.
Remember that new batterys require a break in period before you will get full power from them. Look at Trojan Battery site for the best info out there on all aspects of batterys.
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Unread 05-25-2009, 10:02 AM   #3
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Default Re: 82 CC DS Solenoid Check

Just 2 side notes here....... just because a solenoid clicks doesn't mean that it is making contact. It could be burnt up inside...... and check your resistor coils for breaks. Wait until they cool and pull and push on the ones that are not working......
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Unread 05-25-2009, 12:47 PM   #4
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Default Re: 82 CC DS Solenoid Check

Old Mec, I'm fortunate to have a neighbor who not only tinkers some with carts but also owns a couple of Batteries Plus stores. So I let him know I was needing batteries and a few days later he came over with a fresh tested set!!!! I knew if I removed the batteries I'd forget something so diagramed the main wiring (those I might have anything to do with). I do have the same problem, just more power. I suspected this is where I'd end up but being a rockie, and not have the luxury of wasting cash on stupid mistakes, I found you!!
ScttyB, Having read some other threads I went out and raised the cart up to do the tests. It help me elliminate a few things and narrow my wordy questions. The resistor coil I assume is the sections of coil connecting several of the later solenoids. This seemed solid and secure. With a test light I got positive current from the throttle switch box thingy with each click. I think I've done a fair check, but ignorance is bliss, and I adhere to questions are only stupid if gone unasked.
Thank for your help.

I live ad play outdoors with my big dogs, EK
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Unread 05-25-2009, 01:07 PM   #5
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Default Re: 82 CC DS Solenoid Check

I apologise, Old Mec. I failed to respond to your first question of the responce of the solenoids as they made contact. Having read though a few other threads I new that there would be no motor responce on activation of the first one. So, I'm not sure if that means #one is good or may be bad???
# two(first speed) I get current and the click but no motor activation, same with #three( second), but #4 kick the motor obviously directly into the third speed with a jerk, spilling my water buckets!! I get a positive increase with #5 solenoid. I hope that explains my senerio a bit clearer! Thanks.


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Unread 05-25-2009, 01:35 PM   #6
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Default Re: 82 CC DS Solenoid Check

The solenoid closest to the driver's side is the master. It clicks (closes) first to put power to the all the rest ..... Your next two are bad. As we have discussed on BGW before these solenoids are now 25 yrs old and activated each time somebody pushes the gas peddle.... Sure the low speeds will go out first and you can just replace the 2 in question.... But, wouldn't it be prudent to change them all once you see what a pain it is to disassemble you will wish you had when the others go bad in 6 mos Good luck
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Unread 05-25-2009, 01:41 PM   #7
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Default Re: 82 CC DS Solenoid Check

OK Empty Keg, you seem to have the following #1 solenoid OK, #2-#3 solenoids not making contact for some reason. External poor connections or MORE LIKELY internal contacts burned and NOT making contact. I would double check ( contact bar ) to confirm power input to #2 and #3 solenoids. Until you loose two solenoids in a row you wouldnt notice so much the lag in power. Then Do as SCOTTYB says and double check resitors between the solenoids that dont operate correctly. Be sure that the connections are good and tight and that there is NO cracks in coils.Then I would purchase ONE NEW solenoid and add it in # 2 position and confirm operation, then replace #3 solenoid and you should be up and running.
The reason I say do one solenoid at a time is to insure you dont have other problems? In electrical work there are so many things that can cause problems that I have learned through the years to work with care, step by step and for you even more so.
Remember there is NO STUPID QUESTIONS JUST UNASKED ONES?
I hope this will solve all your problems and gets you back to playing with your BIG DOGS.
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Unread 05-25-2009, 07:37 PM   #8
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Default Re: 82 CC DS Solenoid Check

scottyb, Old Mec,
Yep, I wouldn't have known except for ya'lls help and responces on the other threads and I didn't have to leave home! I'll break down and order some solenoids. Thanks.
P.S. My wife took one of our females to a Group Second at the AKC dog show this weekend at Harriman, Tenn.

I live and play outdoors with my Big Dogs. EK
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Unread 06-06-2009, 11:41 PM   #9
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Default Re: 82 CC DS Solenoid Check

Update on my 82 CC. Installed the solenoids last week, carefully cleaning all electrical connections. All speeds work as supposed to, but it does not have much power at these slow speeds?? EK
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Unread 06-06-2009, 11:45 PM   #10
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Default Re: 82 CC DS Solenoid Check

WHat do you mean? It has more power at the higher speeds? Have you checked the battery pack voltage? We need to know the condition of the battery pack if we are to assess a power problem
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