2005 Club Car DS intermittent no pedal response

spuds

Long time lurker, first time poster. I've read through a number of the posts here (and done several searches), and think we have an OBC problem, but wanted to sanity-check first.

2005 Club Car DS. 48V. Power Drive charger. Cream colored OBC.

New 8V US batteries and battery cables.

Had the symptoms for a few months before the new batteries (which got to the point that they wouldn't charge up properly or hold a charge).

Sometimes when we depress the "go" pedal there is no response. This happens either forwards or reverse. It has happened from a complete stop and also from a "coast". Battery pack measures good, charges well (we're following the break-in process posted here), and is holding good voltage. All connections appear clean and tight. Repeated pressing the "go" pedal eventually gets the cart to move.

Today the symptoms got worse in that the buzzer doesn't sound when you initially put the F-R switch into reverse. It took several cycles of the key and the F-R switch to get the cart to respond with buzzer and movement. At this point, returning the F-R switch to neutral causes the battery light to illuminate (pretty much solid). Battery light went out when the "go" pedal was pressed again.

We tried the OBC reset procedure twice. Neither time would the buzzer sound during the reset procedure (nor did we hear any other sounds). No change in the behavior.

At first I thought (after much reading here) MCOR since throught we heard the solenoid click and the charge light stayed out, but now I'm thinking OBC. Does this conclusion makes sense?

Many thanks for a helpful forum!

Michelle

BGW

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OLD MEC

Is cart series or IQ? lever F&R control ( series ) or rocker switch both located under drivers leg ( IQ with run tow switch ). If you are hearing the solenoid click each time pedal is depressed you may have a bad unit? Just because solenoid clicks doesn't mean internal contacts are working. jack up differential and hold with auto type jack stands, then block front wheel in both directions and jumper with a 6 guage wire across both ( large leads ) on solenoid then try and see if motor runs? WARNING ONLY ALLOW MOTOR TO RUN FOR A FEW SECONDS AS IT CAN EXPLODE AND POSSIBLY THROW METAL YOUR DIRECTION.

spuds

IQ (sorry, meant to include that in the original post)

14Kuntry

I just had the same problem. Pull your F&R switch off and make sure everything is connected tightly. I had a terminal loose and it burnt up the switch. I'd start with making sure all the wires are tight.

spuds

Thanks for the input so far. We've checked all the battery, OBC, and F/R switch connections and all are clean and tight. The problem is extremely intermittent so we have not tried jumpering across the solenoid (also would need to borrow some jackstands, etc. to do this. Got rid of ours when we downsized).

More symptoms though - it acted up twice earlier today. Initially on start-up, key on, put the F/R switch into reverse, no reverse buzzer until stepping on the go pedal and the battery light came on when we stopped. Switched to forward, step on go pedal, light goes out and it moves fine. It didn't act up for quite a while after that, through quite a few stops and starts.

Once, from a complete stop, definitely heard the solenoid click on and off yet no cart movement. Tried several more times, cart would lurch forward very briefly, then nothing. After a few minutes or so of getting just a slight "bump" of movement, it finally drove normally after the go pedal had been held down for several seconds. Didn't act up once after that.

With it being so intermittent, it's frustrating to try and diagnose.

Michelle

BLakeside

spuds This sounds exactly like a solenoid going bad. There could be other problems but the solenoid is most likely the problem and the easiest and least expensive place to start, other than cleaning all 6 or 4ga wire connections. Test as OLD MEC stated to confirm solenoid. Then let us know.

Barry

OLD MEC

I know how hard it is to find a intermitant wiring problem as I spent alot of years specializing in this very field in autos, and trucks? Just ask SCOTTYB about his problems with IQ wiring some time? Some thing like this can be in so many different items or wiring that its just a matter of tracing every thing and try and narrow it down. I hate to say this but it could also be in your controller itself in this case? You said you checked F&R switch but you might try a high resistance test with Volt Ohm digital meter at switch or connections? Its also a possiblity that the MCOR unit could have a bad micro inside ( I have 5 defective MCOR units that had micro only problem ) causing same type of problem? I would unhook each wiring loom connector and look for water damage and reconnect several times to wipe contacts. Being a IQ cart it could very possibly be the F&R rocker switch causing problems as I found many here near ocean that would act like yours and only work part of time? To confirm you might try and jump between the center feed wire should be ( Red-White strip ) to either Blue ( Forward ) or White ( Reverse ) if same as 2000-2003 models I have diagram of? Try this for some time and see if problem is gone? I know its hard to only go forward but if you pick a route that you can loop around and try it several times?
From your answer sounds like you might have been like me and down sized and got rid of many of my tools when first moved down to Texas?

jgerfers

This is to Spuds or anyone with answer. After reading all the above posts no resolution was posted. Am I to think the problem was never solved or just not posted. I have exact same issues with my 2004 Precedent. I have replaced the MCOR module the solenoid by pass the OBC and bought smart charger and replaced the F&R switch to the tune of $1000 and still the problem exists. So my question is did Spuds figure her problem out or not. Does anyone have insight to this problem. Thanks

spuds

Unfortunately, still having the intermittent problem. The only thing we haven't gotten around to doing is the MCOR (car has new solenoid, new OBC).

I did recently download the MCOR troubleshooting guide and we'll be going through the procedure as soon as we have some stands so we can safely get the back wheels off the ground.

Michelle

Stevec3201

Might as well just replace the motor and see if that doesn't fix it