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Unread 02-04-2011, 10:58 PM   #1
K&K
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Default '99 Club Car DS won't go

Thanks in advance for ANY help.

Just replaced the batteries (old ones were close to shot). Cart ran fine for about a week after. Then I noticed the cart would not always respond to the gas pedal being pushed. After pumping the pedal, it would go. It might have taken two or three pumps of the pedal, but then it would go. Finally, cart gave out about 1/4 mile from home no matter how many pumps. I started pushing the cart with the family aboard. I told my wife to just keep her foot on the gas. About half way home the cart just started to run (yelled to my wife to keep on going till home and I would just walk). I thought it was bad battery cables so I replaced. Backed the cart out of the garage no problem. Put it in forward and - nothing. Pushed back into garage and tried again - now it wouldn't go in either forward or reverse! Thought it was solenoid as this had happened to me once before. After changing the solenoid out, still nothing. Checked limit switches, potentiometer, OBC, controller - all check out. The cart will "lurch" slightly in either direction when gas pedal is pushed now, but then nothing. Wondering if this may be bad motor brushes? Any help or advice is very much appreciated.

P.S. nearly all my knowledge of golf carts comes from this forum (this is just my first time posting)
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Unread 02-05-2011, 02:23 PM   #2
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Default Re: '99 Club Car DS won't go

NEED little more info please.
#1 Does your cart have a F&R lever under right leg ( series motor ) OR a F&R rocker type switch ( Shunt Regen Motor ) as diagnoses is different?
#2 Does the solenoid click each time pedal is pressed with key on, F&R control is forward or reverse?
#3 Have you been hooking up charger each time after any usage of cart? Have you checked battery pack voltage and each battery for comparison to STICKYS "State Of Charge Readings"?
NOTE NEW BATTERYS REQUIRE full charging after each use to bring battery pack up to full voltage ( 30-50 discharge-recharge cycles ).
Your problem may be as simple as defective battery, wiring, controls, or even motor itself BUT FIRST lets be sure you have correct power ( like testing a carb because gas tank is empty? )
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Unread 02-05-2011, 09:05 PM   #3
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Default Re: '99 Club Car DS won't go

First off, old Mec, thanks for the quick reply. I'll try to answer your questions in order to the best of my knowledge.

1 - The cart does have a F/R lever under the right leg and not a rocker switch.
2 - I can't honestly say that I hear the solenoid "click" each time the gas pedal is pushed in either direction. What I do know is that I had already replaced the solenoid about 3 years ago (because it WAS bad - and subsequently worked after replacing). According to the trouble-shooting guide I'm using and the multimeter readings though, the solenoid is working. Also, I bought another new solenoid and tried it out to no avail.
3 - Yes, I charge the batteries after every use and have tested the voltage. The batteries are new and give a reading of 51 volts. Not exactly sure what STICKYS means, but I think it is the sticker with month/year of battery stuck on top of batteries. In that case, the STICKYS read 11/2010.

I really do wish it was just giving the batteries a full charge as I think that would save me several hundred dollars. I spoke with a local golf cart shop today and he seemed to think that it could be the motor brushings, but would not commit to that being the cause (understandably) without checking it out. He mentioned taking the motor off to investigate (which is out of my league). I'm getting the feeling that I've troubleshot as much I can without getting over my head. If you think there is something else for me to check on, I'm more than willing to listen!

Again, thanks for your response and I hope you can help me more before giving up to a local "pro" and paying more than necessary.

Great site y'all have here!!
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Unread 02-06-2011, 09:42 AM   #4
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Default Re: '99 Club Car DS won't go

OK now forum can help you diagnose your problem if you . The STICKIES are above your posts when you click on Club Car Electric at top of page ( GREAT INFO ON MANY SUBJECTS ) The 11/2010 means batterys were made in November of 2010.
What you have is a series motor cart. From your post I would assume the solenoid is OK because you replaced it, but ( IF ) its not clicking. If it is clicking EACH TIME PEDAL IS PUSHED you have other problems, but lets eliminate as you test items??
#1 Next to check is the micro switch on back of F&R control ( there are 3 stacked ) and the FIRST one against body of control is in solenoid circuit. Check by moving F&R lever back and forth and see if micro clicks ( very little sound so be very close to confirm ) or if you have a digital volt meter check for voltage across both wires when key switch and F&R is in Forward or reverse. If it clicks or has voltage across wires ( white with black stripe and green with white stripe ) then we look elsewhere. IF NOT GO TO #2
#2 check dash key switch for power to and from ( if reverse alarm works you have power ) If you have power out of key switch the next item to check is speed control.
#3 The continously variable potentiometer is under drivers floor connected directly to pedal shaft, is the above indicated speed control. Check that the blue wire from key switch is powered at plug in on pot and when pedal is pushed the green with white stripe coming out should have power ( remove cover and you can see micro that must close to power up solenoid ) IF power is there then NORMALLY its the potentiometer itself ( which is no longer available from CC ) but could be purchased from after market sourses? I would not go this route but replace with conversion kit that updates you to MCOR which has been used since about 2000.
Hope this gives you a start and let us know what you find.
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Unread 02-08-2011, 10:18 PM   #5
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Default Re: '99 Club Car DS won't go

I really appreciate all the advice. However, using the CC troubleshooting section in the manual, I've eliminated the possibilities you've mentioned to check. Unfortunately (for me), I've exhausted the options I feel are within "my league". I'm turning it over to a local shop and seeing what they can find. From what I've read here and in other forums, it appears that it may be the brushes in the motor. Taking the motor off to check is a bit out of my expertise and I don't have to the tools or means to do it. The cart goes into the shop tomorrow and I'll let you know what they tell me.

Thanks again!
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Unread 12-31-2011, 01:29 AM   #6
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Default Re: '99 Club Car DS won't go

Hi. Sorry to resurrect an old thread, but what did the shop find with your cart? I have a 2001 ds with the same symptoms.
When it sits for any length of time, it will take a few pumps of the accelerator to before it will move, and it only "wakes up" at full throttle, which is rather unsafe.
My cart has new 4gauge cables and the batteries are pretty good (2010). Motor brushes sounds like a logical culprit considering it acts up after sitting for at least 10 mins or more. I'd love to know what solved your problem,

Btw, my solenoid clicks whenever the accelerator is pressed.

Any help is appreciated.
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Unread 12-31-2011, 09:53 AM   #7
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Default Re: '99 Club Car DS won't go

Quote:
Originally Posted by njncdmjt View Post
Hi. Sorry to resurrect an old thread, but what did the shop find with your cart? I have a 2001 ds with the same symptoms.
When it sits for any length of time, it will take a few pumps of the accelerator to before it will move, and it only "wakes up" at full throttle, which is rather unsafe.
My cart has new 4gauge cables and the batteries are pretty good (2010). Motor brushes sounds like a logical culprit considering it acts up after sitting for at least 10 mins or more. I'd love to know what solved your problem,

Btw, my solenoid clicks whenever the accelerator is pressed.

Any help is appreciated.
you might get a bit further if you start yourself a new thread.......give all the info you can.......................................
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Unread 12-31-2011, 12:26 PM   #8
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Default Re: '99 Club Car DS won't go

thanks... will do. happy new year
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Unread 12-31-2011, 12:27 PM   #9
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Default Re: '99 Club Car DS won't go

Quote:
Originally Posted by njncdmjt View Post
thanks... will do. happy new year



same to you and yours...................................
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