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Unread 05-30-2010, 05:12 PM   #1
Not Yet Wild
 
Join Date: May 2010
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Default Motor Controller troubleshooting

My 1996 club car will not run. When I push on the accelerator pedal the machine will only move a fraction of an inch. How do I know for sure if the controller is good or bad? Where can I find a manual or a gudie to aid in troubleshooting?
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Unread 05-30-2010, 06:51 PM   #2
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Default Re: Motor Controller troubleshooting

When asking for info always give make, model, year and if in doubt give us sertial number below passenger glove box. Is your cart a regen or a series? Series has a LEVER under your right leg that swings from side to side, while a Regen has a rocker switch mounted in same position on a black box afair.
Are you getting a click when stepping on throttle, if you are it means solenoid is engaging? BUTthat doesn't mean is good and if in doubt do the following
1- Jack rear wheels up off ground and place blocks under axle away from tires from turning
2-Block solid front wheel from going in either direction
3- Using a heavy gauage cable make contact at ( both large posts on solenoid ) for a few seconds and if that works the solenoid will need to be replaced
BEWARE IF MOTOR RUNS DO NOT ALLOW MOTOR TO WIND UP AS YOU COULD GET A FACE OF MOTOR ARMATURE
Have you done basics like checking batterys for distilled water, for charge condition and all cable connection are good?
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Unread 05-31-2010, 02:38 PM   #3
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Default Re: Motor Controller troubleshooting

Thanks for the tip on posting!
The cart is a Club Car 1996 model, it must be a series model as it has a for/rev lever. The batteries are in good condition although not new, maybe three years old. The water level is fine. the cables are new. The voltage is 49-50 volts fully charged.
I did try the heavy guage wire to jumper around the solenoid the car would go. So I replaced the solenoid but it still reacts the same. the diode across the main contacts appears to be good also. Is there a resistor across the coil posts of the solenoid?
Another thing, the car was running fine. But the cables were a bit corroded (?) so I changed them. when I changed the one on the solenoid I must have touched the negative cable or something cause there was a small spark. When I finished the car would not run. Now I know my mistake was I should have removed the negative cable first and replaced it last. Could this have caused a spike on the contoller and trashed it?
Thanks for any help.. Sorry I got long winded with my problem.
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Unread 05-31-2010, 02:41 PM   #4
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Default Re: Motor Controller troubleshooting

As for if I am getting a click when I step on the pedal the answer is "yes", a click from the microswitch on the accelerator pedal, and "no", there is no click from the solenoid.
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Unread 05-31-2010, 03:26 PM   #5
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Default Re: Motor Controller troubleshooting

I am not an expert but if you arced a wire attached to the controller it is most likely toast. I had a similar situation on a cart as far as your description of what it does and it ended up being the controller. It would shutter forward slightly in reverse and forward.

I have learned, disconnect all power and empty the system before doing anything with the wires. I don't know the specific troubleshooting steps to test the controller. I solved mine by a process of elimination.
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Unread 06-01-2010, 11:51 PM   #6
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Default Re: Motor Controller troubleshooting

Thank You
I was thinking that was my problem but didn't really want to believe it. So now I have to decide if I want to spend the money for repairs or trade it for a newer one.
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