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Unread 05-31-2009, 11:38 PM   #1
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Default '85 36V CC - Forward Slow, Reverse No

I have a 1985 36V electric Club Car that runs slow in forward with no climbing ability and does not run in reverse.

The solenoids were checked with 36V, 2 were replaced due to suspected cracks in case. All tested fine with volt-ohm meter. They can audibly be heard activating.

The resistor coils are not burnt or touching.

The micro switches can be heard by depressing the pedal with the key switch off. I took the red plastic cover off to make sure nothing was broken, but I did not replace them. All I did was blow out the dust.

All battery to battery cables have been replace with 4 gauge wire. The other cables and connections were all checked and cleaned.

The cart runs in forward but does not have any acceleration, just a constant slow speed and no climbing ability.

The cart does not normally run in reverse at all. If I 'play" with the F/R switch I may find a setting where it will 'jerk' slowly in reverse.

The batteries were replaced in 2007. They were topped off with distilled water and after extended charging and a 'rest period' they tested 6.16 - 6.22 volts each.

Any suggestions why this cart won't go?
1. Batteries? Can they be bad after only two short summers? Should I test with a hydrometer also?
2. F/R switch? Could this be the cause for no reverse?

PS Previously when I depressed the pedal to go up a hill, it felt like the cart went into another gear/speed. This is no longer the case.

I know there is a similar recent post on the site right now. I have read it and others but am still looking for help.
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Unread 05-31-2009, 11:48 PM   #2
nimda
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Default Re: '85 36V CC - Forward Slow, Reverse No

Check the F/R switch contacts. Also, check ALL the micros with a volt meter to make sure they are working.

The batteries "could" be a little weak if they have been sitting discharged for 2 years. Get them charged back up and topped off with distilled water. I would imagine after several cycles you see them perk back up a bit....MAYBE.
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Unread 05-31-2009, 11:59 PM   #3
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Default Re: '85 36V CC - Forward Slow, Reverse No

I can be wrong but here is what I think..... All solenoids can be heard clicking but only low speed available... The solenoid closest the driver side is the master, next is low speed and the med low, med, and so on. You need to get the cart on blocks and depress the peddle and see if only the low speed is working even though you can hear the solenoids does guarantee they are working. You can test them with a voltmeter or and I suggest you replace them all..... They are all the same 20+ yrs old and will all last about the same, so you can expect the others to fail shortly in my experience.... good luck
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Unread 06-01-2009, 12:07 AM   #4
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Default Re: '85 36V CC - Forward Slow, Reverse No

Quote:
Originally Posted by scottyb View Post
I can be wrong but here is what I think..... All solenoids can be heard clicking but only low speed available... The solenoid closest the driver side is the master, next is low speed and the med low, med, and so on. You need to get the cart on blocks and depress the peddle and see if only the low speed is working even though you can hear the solenoids does guarantee they are working. You can test them with a voltmeter or and I suggest you replace them all..... They are all the same 20+ yrs old and will all last about the same, so you can expect the others to fail shortly in my experience.... good luck
I will put it on blocks and test again, BUT I tested each solenoid individually with 36V applied and a volt-ohm meter. After replacing 2, they all tested fine. Incidentially, I replaced number 1 and number 4.
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Unread 06-01-2009, 12:10 AM   #5
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Default Re: '85 36V CC - Forward Slow, Reverse No

Sounds like you already know how this system works.... If there is power to the micros and activation of each solenoid then only a bad connection, broken wire or coil could interupt the power from getting to the motor?
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Unread 06-01-2009, 12:10 AM   #6
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Default Re: '85 36V CC - Forward Slow, Reverse No

Quote:
Originally Posted by roady89 View Post
Check the F/R switch contacts. Also, check ALL the micros with a volt meter to make sure they are working.

The batteries "could" be a little weak if they have been sitting discharged for 2 years. Get them charged back up and topped off with distilled water. I would imagine after several cycles you see them perk back up a bit....MAYBE.
Can you describe in a little more detail how to check the F/R switch and the micro switches?

The batteries have been used annually (May-October) since they were installed in 2007. They are fully charged at the end of each season and the cables all disconnected. Should they register more than 6.20 volts?
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Unread 06-01-2009, 12:14 AM   #7
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Default Re: '85 36V CC - Forward Slow, Reverse No

Quote:
Originally Posted by scottyb View Post
Sounds like you already know how this system works.... If there is power to the micros and activation of each solenoid then only a bad connection, broken wire or coil could interupt the power from getting to the motor?
I only know what I have learned on this site, which has been helpful.
The F/R switch may be the reverse problem, but I don't see how it can be the slow forward speed problem.

If the batteries are weak, but the solenoids activate, should the cart still accelerate?
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Unread 06-01-2009, 12:21 AM   #8
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Default Re: '85 36V CC - Forward Slow, Reverse No

NO. post the pack and individual battery voltages here.... no need to disconnect anything to get these readings

2 reasons to have the rear wheels off the ground and the seat removed ....
1. you can hear and see it go thru the gears or not
2. no ugly surprises = ie: cart lurching
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Unread 06-01-2009, 12:09 PM   #9
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Default Re: '85 36V CC - Forward Slow, Reverse No

what he said ,
the reverse normally uses 1/2 the pack Voltage so if the cart is barely moving in Forward
it may be 2 week to move at all in reverse.
Having the wheels up will answer this !

Also while you have it up on blocks take the 2 rear wheels off and clean the wheels
and breaks (2 years is a long time for rust to build up)
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Unread 06-07-2009, 01:17 PM   #10
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Default Re: '85 36V CC - Forward Slow, Reverse No

Okay, I finally got a chance to check more (the cart is located about 150 miles away).

I jacked up the rear wheels, put the F/R switch in F, turned on the key and depressed the foot pedal.
Solenoid #1: Clicks, no wheel rotation
Solenoid #2: Clicks, slight wheel rotation (I had to give the wheels a slight turn by hand to get the wheels turning)
Solenoid #3: Clicks, faster wheel rotation
Solenoid #4: Clicks, even faster wheel rotation
Solenoid #5: Clicks, even faster wheel rotation

My conclusion: the solenoids and micro switches are working okay. Do you agree? Not sure about Solenoid #1, but it is brand new (just replaced it). I did notice that the motor (brushes?) made some noise. Is this normal? Or should the motor be essentially silent?

The batteries were tested.
They had not been charged for 2 weeks.

Current voltage (voltage 2 weeks ago)
Battery #1: 6.10 volts (6.16 volts)
Battery #2: 6.10 volts (6.16 volts)
Battery #3: 6.12 volts (6.19 volts)
Battery #4: 6.13 volts (6.19 volts)
Battery #5: 6.09 volts (6.15 volts)
Battery #6: 6.09 volts (6.14 volts)
Entire batter bank: 36.6 volts

These reading would seem to indicate about 60% charge, with a max of about 70% even after extended charging.

The batteries were purchased new at Sam's Club in May 2006. So they have been used 3 summers. Is it time to replace them?

Finally, when the car was jacked up, I tried reverse. The wheels shuddered, but did not run in reverse smoothly. This is the same symptom I have when I try it normally. I have to 'push start' in reverse and the cart just slowly jerks backward. Suggestions?
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