Need Help! 1984 CC solenoids???

jallen28145

Ok guys, I need some help. My dad just bought a 1984 club car electric. Decent shape, good batteries, but it won't run right. When he bought it, the guy said it may need a f/r switch, but he didn't know much about it. When you put in either forward or reverse, key on or off, the f/r switch would arc and spark and it would move without pushing the pedal or even turning on the key. I thought it was just a stuck solenoid and told him to buy it, easy fix. My buddy has a 1989 CC and the same thing happened to him and it was a stuck solenoid in the front of the cart, under the f/r switch. Well this 1984 CC doesn't have that solenoid up front, only 5 solenoids in the back. So, I took my test light and found that the solenoid on the far right (drivers side) was stuck, test light was on constant. Well, I tapped it with a screwdriver and the light went off, so I figured I'd found the problem, stuck solenoid. Now it wont go at all, no movement or sparks at the f/r switch or anything with the key on or off, nothing. I looked over the wiring and all looks good, I have juice at the speed switches and all that looks good.

What could the problem be and how do I test the solenoids? Does power come in from the passenger side or driver's side solenoid? I have a hunch that the problem is in one of those solenoids but I can't get it figured out! If one is bad does that kill the whole cart? Is there a way to bypass them to test them? I need help, I have an EZGO, not familiar with these CC's!

Thanks guys!

BGW

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OLD MEC

The flow of power is from ( drivers side ) #1, #2, #3, #4, #5 to ( passenger side ). Number 1 drivers side ( MAIN ) solenoid feeds power to the flat buss bar that connects the other 4 solenoids so if this solenoid does not make internal contact the rest have no power. The large coil resistors connect from #2,#3,#4 solenoids cutting speed
Sequence is as follows through pedal travel #1 ( main feed solenoid ) feeds power at large solenoid posts to #2-#3-#4-#5 NO MOTOR POWER, #1 and #2 closed sends power through all 3 large resistor coils "SLOW SPEED", #1 and #2 and #3 closed power through 2nd and 3rd resistor coils for "MEDIUM SPEED", #1 and #4 feed through #3 resistor coil on passenger side resistor coil "MEDUIM HIGH SPEED", #1 and #5 solenoid by passes all resistors giving full power to motor "MAX SPEED".

jallen28145

Thanks for the reply. How can I test the solenoids and what do the symptoms sound like the problem is?

Thanks again for the help!!!

jallen28145

Ok, so I have made progress but still not quite there. I swapped #1 and #5 solenoids thinking the #1 was/is bad. When you press the pedal you can hear 5 distinct "clicks" and the cart WILL move forward when the pedal clicks at 2, 4 and 5. No movement on the first click of the pedal, or the 3rd click of the pedal. Also there is NO MOVEMENT in reverse??? I can deal with forward like it is but I would like to have reverse!

What makes the cart move in reverse and how can I get reverse?? Can I move the big white wire from solenoid #1 to #2? Or is it the big black wire on solenoid #5 that I should move?

Thanks again for the help!

scottyb

Solenoid #1 is the master, located closest to the driver side. When it clicks power is fed thru and ready at the other solenoids. Solenoid 2-5 are 'gears' or speeds.... The same system works forward and reverse.... DO NOT SWAP CABLES AROUND LOOKING FOR REVERSE!
Replace solenoids the do not function and for reverse look at the reverse micro or bad contacts in the F&R?

jallen28145

Thanks for the help. I think I've got it figured out. After making sure the wiring was right on the f/r switch it turned out to be a bad contact on the switch itself. Now she goes forward and backward!

Thanks again for all the help!