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Unread 09-30-2009, 10:00 AM   #1
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Default 95 CC Intermittent Forward Problem

I have a 1995 CC 36 volt DS that intermittently stops when I let off the accelerator. It if I wait a couple of seconds it will eventually go. It seems like when it will not go forward it will still go in reverse. I printed wiring diagram 890336VPW2 from this site and that print is pretty accurate. While checking the wiring I noticed a couple of things. Most of the major electrical components have been changed. The motor is a 36/48 volt motor from Santiago Golf Supply, the controller is a Curtis CON-1204-RB 400 amp, and the solenoid is a White-Rodgers 586-117111. The solenoid is shown as an intermittent duty 200 amp solenoid on White's web site. The solenoid coil does not have a diode across it. I assume the diode is there to clip voltage spikes. Is the solenoid too small and can the absence of a diode be affecting the controller? Any other advice on what might cause this problem would be greatly appreciated!
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Unread 09-30-2009, 10:09 AM   #2
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Default Re: 95 CC Intermittent Forward Problem

Sounds like an intermittent F&R switch to me?
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Unread 09-30-2009, 01:24 PM   #3
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Default Re: 95 CC Intermittent Forward Problem

Quote:
Originally Posted by scottyb View Post
Sounds like an intermittent F&R switch to me?
Ya, I looked at it last evening and thought it looked worn. I might tear it apart this evening. Are the contact points were the power wires attach supposed to turn?
Thanks,
Frankie
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Unread 09-30-2009, 01:32 PM   #4
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Default Re: 95 CC Intermittent Forward Problem

Yes they swivel to keep from constantly bending the cable that is attached to it....
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Unread 09-30-2009, 01:54 PM   #5
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Default Re: 95 CC Intermittent Forward Problem

I've been looking at the HD switches on some of the sponsor sites. They show one for 96 and up 48 volt or 94 and down 36 volt. What do I need for a 95 36 volt?
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Unread 10-01-2009, 10:31 AM   #6
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Default Re: 95 CC Intermittent Forward Problem

Call the sponser , tell him what you have , then if he sends wrong one it's his dime to correct it.
These are all good guys and easy to work with of they would not be here.
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Unread 10-05-2009, 09:37 PM   #7
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Default Re: 95 CC Intermittent Forward Problem

OK here's the next chapter. On Friday I took the f/r switch off of the cart as Scottyb suggested and disassembled it for inspection. Everything on the switch looked good. In fact so good it must have been replaced recently by the previous owner. I did however find a couple of questionable terminals. I cleaned the connections, put it back together, and took it for a test ride. It worked fine. Sunday the wife, kids, and dog go for a ride and it lets them sit. She said it did the "won't go in forward but would in reverse thing" once, then it worked OK for a while, then quit all together. I looked at it this afternoon. I checked the solenoid and read 38 volts whether it was energized or not. I noticed a noise like the motor was running and it was trying to go when I pushed the accelerator the whole way down. I had a clamp-on meter on the solenoid wire and it was pulling 95 amps. I crawled under the back of the cart to see if something was broken and found the white and the blue wires that come from the f/r switch melted together at the controller. I'll make up new wires tomorrow but I hope the short hasn't damaged the controller! Stay tuned for the next update.
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Unread 10-07-2009, 01:04 PM   #8
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Default Re: 95 CC Intermittent Forward Problem

I replaced the bad wires with #2 welder cable and the cart seems to be working fine now. I did notice that the cart will run up hill fine as long as we are moving when we start up the hill but it will not start from a standstill on a hill. I assume this is because of the 22" tires kill the power. What do youinz think?
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Unread 10-07-2009, 02:54 PM   #9
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Default Re: 95 CC Intermittent Forward Problem

Look at all your wires they should have been upgraded to at least #4 when whom ever
upgraded the controller to 400 Amp
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Unread 10-08-2009, 09:37 AM   #10
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Default Re: 95 CC Intermittent Forward Problem

All the wires where #4 except for the blue and white wires comming from the F/R switch. We ran the cart all over last evening and it worked good. Thanks for the help.
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