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Unread 09-17-2009, 05:15 AM   #1
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Default club car problem help

Wow session timed out and i have to start all over. here goes

I got this old club car golf cart that someone gave to us and iv been working on it for about a week.

I had pulled everything that looked important from it and rigged something up to recharge the batters witch now give off exactly 36 volts.

After i had hooked everything back up and flipped the switch(in-place of key) put it in forward and pressed the gas, all i got was a click from what i believe to be the resistor assembly. It also clicks louder and more frequent when i press harder on the gas.

I'm sure i hooked some things up wrong but what i believe to be the problem is a little unidentified black box that has 2 wires. 1 is yellow and connects from the negative of the first battery and the second is white and goes to the left beginning side of the resistor assembly. In the photo you can see it on the right but i had removed it from its box and up close it has a copper coil witch makes me think its a voltage reducer.
EDIT: there is also a stray yellow wire that comes from the forward/reverse switch that is hooked up to a heaver white one. it was like that when i got it so i don't know where it goes.(second pic)

Images
http://www.bbtgp.net/toy/













i have no clue what the year or model it is but if you have any suggestions on locating it please do tell. If no one knows the problem thank you anyways, im satisfied that i even got it to click :). Thanks for your help.
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Unread 09-18-2009, 03:20 AM   #2
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Default Re: club car problem help

I guess this is going no where, i managed to hook the battery up to the motor and it doesn't spin to well, like the axle is bent or something else.
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Unread 09-18-2009, 08:45 AM   #3
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Default Re: club car problem help

I'm not real familiar with resistor carts but I do know that if your batteries are only reading 36v after a full charge they are shot. they should read almost 39 when fully charged.
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Unread 09-18-2009, 08:59 AM   #4
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Default Re: club car problem help

Well im having problems with one of them now. I can only get the motor to spin when the battery in the lower right hand corner isn't hooked up. So i tested it with out and hooked up the charger to the motor and had it spinning pretty fast and there is some rubbing on the axle. Ill guess ill just keep tinkering with it and i don't think i need speed control though, more like a drag car now.
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Unread 09-18-2009, 09:14 AM   #5
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Default Re: club car problem help

Okay! Lets start at the beginning ...... Welcome to BGW
You have a 5 solenoid speed control system. CC made them like yours from 1982-88. The year can be found in the first 2 digits of the serial #. (ie = A8577777743 is a 1985 cart) The battery bay looks like a rats nest of wires Use these diagrams to eliminate all of the extra stuff for now... THe little black thing is the reverse buzzer. don't worry about it yet. Post digital voltage readings for each battery like #1= 6.13, #2= 5.98 etc.

Avoid spinning the motor with no load( on jacks) It can explode! Check that the brakes are not binding...... Check that the micro switch at the F&R is working.... When you say clicking doyoumean in rapid seccession when you push the peddle cuz that is a low voltage indication. 36v is empty for that pack!
Attached Images
File Type: jpg clubcar021002pg56solenofh6.jpg (5.8 KB, 183 views)
File Type: jpg Z ____ 5 SOLENOID CC.jpg (73.4 KB, 31 views)
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Unread 09-18-2009, 09:24 AM   #6
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Default Re: club car problem help

Stick with it. The guys on this site really know thier stuff!
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Unread 09-18-2009, 09:47 AM   #7
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Default Re: club car problem help

Quote:
Originally Posted by scottyb View Post
Okay! Lets start at the beginning ...... Welcome to BGW
You have a 5 solenoid speed control system. CC made them like yours from 1982-88. The year can be found in the first 2 digits of the serial #. (ie = A8577777743 is a 1985 cart) The battery bay looks like a rats nest of wires Use these diagrams to eliminate all of the extra stuff for now... THe little black thing is the reverse buzzer. don't worry about it yet. Post digital voltage readings for each battery like #1= 6.13, #2= 5.98 etc.

Avoid spinning the motor with no load( on jacks) It can explode! Check that the brakes are not binding...... Check that the micro switch at the F&R is working.... When you say clicking doyoumean in rapid seccession when you push the peddle cuz that is a low voltage indication. 36v is empty for that pack!
lets see... it says its an 86. i dont have the volt meeter any more, it was very expensive and i was borrowing it from a friend. When i did test the batterys they all gave around 6 volts, i guessed 6*6=36 but i dont know.

I have to google micro switch and f&r before i could tell you and as for the clicking it depends on whether its in reverse or forward and how hard i push the gas. harder is more rapid clicks and barley pushing just gives one click. Also the batterys just recently started to sound like there boiling, idk about that though, probably a crossed wire.

And i will try to figure out this wiring now.
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Unread 09-18-2009, 09:56 AM   #8
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Default Re: club car problem help

You are going to need a Digital voltmeter. Check this charge chart below. At 50% the batteries are empty. You prolly have battery issues. Yes they do boil a little when charging.... But you need a meter! HF sells a $7 meter that works. The 5 solenoids are the 5 speeds or gears for this cart. The 1st one closest to the driver's side is the master it clicks first powering up the other 4. they should each click ONE time as you press the peddle. ANY RAPID CLICKING indicates a low voltage situation.... Good Luck!
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File Type: jpg StateofChargeChart.jpg (53.8 KB, 29 views)
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Unread 09-19-2009, 04:55 AM   #9
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Default Re: club car problem help

lol, i got the giggles when this thing started moving :) thanks for the help. So all i really need to fix now is the rubbing in the axle and the $500 for the battery's :( thanks again.
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Unread 09-19-2009, 06:29 PM   #10
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Default Re: club car problem help

As per ScottyB's advice, get a meter, they're only $5.
Here's the link:

http://www.harborfreight.com/cpi/cta...emnumber=90899

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