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Unread 07-31-2009, 12:12 AM   #1
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Default '01 48v club car surges with pedal depressed

My '01 48v Club Car DS surges thru diferent speeds with pedal depressed (mostly slow). At times it won't even move at all. I had '05 Trojans T860 and replaced them today with new us batteries of the same grade. No change.

I hear the solenoid clicking, and even if it won't move, it tries a little and then surges for a second. Sometimes it will get going pretty good then slow back down.

The battery warning light doesn't come on thru any of this.

I would appreciate any advice. Thanks!
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Unread 07-31-2009, 11:06 AM   #2
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Default Re: '01 48v club car surges with pedal depressed

Cart serial Number Please !
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Unread 07-31-2009, 04:06 PM   #3
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Default Re: '01 48v club car surges with pedal depressed

AA0146-092665

Cart History:
Lifted in 2005 for construction firm
Used and not well maintained
Stored for 2 years
We bought a 2008 charger from a dealer
Batteries new

Thanks, we bought this for our farm (at a bargain of course!). It's in good shape otherwise.
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Unread 08-01-2009, 08:55 AM   #4
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Default Re: '01 48v club car surges with pedal depressed

Have you checked and made sure that all battery connections are clean and tight? Did you replace you large battery cables when installing new batterys? Old cables may have internal corrosion that can keep batterys from making good connection, battery connections cause most of electric carts problems.
You might start with the solenoid as even though it clicks that doesnt mean that its making contact? From your post it sounds like you motor is trying to run but barely starting IS THIS CORRECT? And at other times only the solenoid clicks and NOTHING HAPPENS CORRECT? If each time your pedal is pushed down the solenoid clicks IS THIS CORRECT? Then we can assume that the MCOR and connecting micro's are working so we can eliminate them for now.
WARNING BEFORE DOING THE FOLLOWING Jack cart up the rear of cart and place on good strong stands ( electric carts can weight up to 1000 pounds ), then block solid the front wheels to keep from any movement. have another person operate the pedal while you do tests and for safety sake. Do you have a digital DC volt meter, and if you do check for pack 48 volts at both of the solenoid large terminals with pedal depressed when solenoid clicks. WARNING DO NOT ALLOW MOTOR TO COME UP TO FULL SPEED AS THE ARMATURE CAN BE DESTROYED AND CAN HIT TESTER WITH FLYING METAL. When wheels are off ground Motors can over RPM's easily SO BE CAREFUL.
If you do not have a meter you could take a 6 guage or heavier cable and touch it across the two large solenoid terminals, this is testing solenoid for bad internal contacts. If the cart runs then you will need to replace solenoid.
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Unread 08-01-2009, 09:02 AM   #5
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Default Re: '01 48v club car surges with pedal depressed

This sounds suspiciously like an ongoing problem I have with an '03 IQ cart. Is you F&R a lever or a toggle switch?
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Unread 08-01-2009, 09:58 AM   #6
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Default Re: '01 48v club car surges with pedal depressed

Yep , not a IQ though (It's the reasin I ask for serial #.)

Go to the stickies http://www.buggiesgonewild.com/electric-club-car/
and see if you see your wiring Diagram !
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Unread 08-01-2009, 02:41 PM   #7
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Default Re: '01 48v club car surges with pedal depressed

scottyb- This cart has a lever for F&R

OLD MEC- I actually jacked her up yesterday to mess with it. Thanks for the safety tips. I took off the MCOR and worked it by hand with no change. I replaced it this morning with a new one just to rule it out. I think it may have fixed it, but the cart needs a charge before I can know for sure. I did install new cables with the batteries, but only replaced the connector on the positive side. The connections seem good, but It sounds like I should get new main cables for the sake of good upkeep. I did check the solenoid for voltage yesterday, and seem to remember good voltage on both terminals whether the pedal was depressed or not which sounds wrong!? I am going to re-check that after it charges.

The cart never quits or dies completely. The best way to describe it is when the pedal is pushed and held steady or full, it varies as if you very moving the throttle up and down randomly, but never shuts off, and never gets you very far before a small hill stifles it.
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Unread 08-01-2009, 02:47 PM   #8
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Default Re: '01 48v club car surges with pedal depressed

gmorrison- my car doesn't have that pie shaped pot like on the diagram shown. I have a copy of my version with the box shaped pot under the frame.
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Unread 08-01-2009, 03:13 PM   #9
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Default Re: '01 48v club car surges with pedal depressed

There should be no voltage on BOTH SIDES OF LARGE POSTS on solenoid except when pedal is depressed and solenoid clicks.
Its a good idea to replace the other cables and if not all be sure and replace the cables to F&R switch as they flex with each direction change. WARNING when removing or replacing cables be sure and use (2) wrenches so as not to turn bolts causing damage to internal wiring. The F&R cables should be good quality flexable high strand count cabling to stand up to so much flexing over time.
Hope this solves your problems and you can start to enjoy your cart.
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Unread 08-01-2009, 08:18 PM   #10
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Default Re: '01 48v club car surges with pedal depressed

I have 50.6v on one side of the solenoid and the other side has the same when the solenoid clicks, BUT, the voltage stays and slowly bleeds down with the cart turned off over about an hour. 15 minutes after, I still had 35v. 45 minutes later, I still had 7 to 10v. This can't be right, but could the solenoid be causing that?
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