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Electric Club Car Electric DS, and Precedent golf cars



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Unread 08-16-2011, 12:57 PM   #1
Not Yet Wild
 
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Default 92 DS Stopped Moving Forward or Reverse

I have a lifted 1992 Club car DS that has been not working like it did! I have 6 brand new trojan batteries that have been all load tested and check out fine! I thought the micro switch went bad and even though they tested good I still replaced all three of them! I have track down and tested all cables and checked for broken wires and made sure they all had continuity with my digital ohms meter! All it is doing is clicking at the solenoid and nothing else. I have jumped out the two large posts on it and the cart still wont move. I have no power going to the motor! I have took apart and cleaned the forward and reverse switch and still no power to the motor! I have not replaced the solenoid cause not sure if that is the problem cause I jumped it out and it still did not work! Can it be the controler went bad? has anyone had this problem and found the fix? Thanks Jimmy
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Unread 08-16-2011, 03:13 PM   #2
The Last Moja Morani
 
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Default Re: 92 DS Stopped Moving Forward or Reverse

welcome to BGW.....when it quit were you riding it or was it like you went to ride it got on and nothing? and if you were riding it when it quit how exactly did it happen.......................................
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Unread 08-16-2011, 04:08 PM   #3
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Default Re: 92 DS Stopped Moving Forward or Reverse

First off thanks for the welcome what a nice site for cart owners.
What first started happening was it was only running at half speed in forward but not in reverse. It did this for a trip to the bus stop Then it went to running slow or like low power in reverse but was working fine in forward full power and speed. I have a battery meter on the dash and it was in the green so figured a loose or broken wire. I parked it over night went to take my son to the bus stop and it would not go in forward or reverse. I opened the seat and notice that one of the microswitches was green and corroted I cleaned it up and still nothing! I since have checked every cable, wire etcwith my meter. I even cleaned up the V-Glide and the forward and reverse switch still nothing just a click in the solenoid when I step on the pedel. I do have power to both large posts and get 36.9 volts on my meter when tested the 2 small posts when pressing the pedal. I have no power to the motor when the pedal is pressed I also have no power in micro switch wire that comes from the controler I got power going in but nothing coming out! I am a forlift mechanic but mostly propane but have worked on some electric pallet jacks so do know the basics what to check for but I am starting to think it is the controller not the solonoid but dont know!
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Unread 08-16-2011, 04:14 PM   #4
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Default Re: 92 DS Stopped Moving Forward or Reverse

if you jumped the soleniod and it still didn,t work than its not the soleniod i,m guessing the controler by the way it acted up before quiting......not being there myself i,m just guessing but what you decribe it doing is one of many symptons when a controler is failing....there are a few very good C.C. techs here so you might want to wait for a few more opinions, but we,ll get it running that much you can count on..............................
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Unread 08-16-2011, 04:16 PM   #5
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Default Re: 92 DS Stopped Moving Forward or Reverse

can the controller be tested to see if its bad?
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Unread 08-16-2011, 05:43 PM   #6
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Default Re: 92 DS Stopped Moving Forward or Reverse

yes but i don,t know the exact procedure......its in the service manual or maybe someone here will know.................................
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Unread 08-16-2011, 08:19 PM   #7
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Default Re: 92 DS Stopped Moving Forward or Reverse

Thank you for the help
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Unread 08-19-2011, 12:02 PM   #8
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Default Re: 92 DS Stopped Moving Forward or Reverse

Club Car is fixed and working better than ever! I just want to say I jacked up the cart and jumped out the two large posts on the solenoid! Nothing happened so I counted out the solenoid which was the wrong thing to do!
I than moved on and after checking and testing every wire and cable there is I figured it was the PMC Controler box. Lucky for me Thoroughbred Custom Golf Carts of Englewood (Which I will add is Great Place to go the owner and staff are Curtious and Very Knowledgeable) had a used controller box and let me try it before I bought it for $75.00! I brought it home and installed it put the solenoid back in hooked up the batteries. The cart moved when I hit the pedal but cut right out again and would not move! However this time I had the seat off and when it kicked out I heard a loud click in the solenoid!. I took my channel lock plyers and while depressing the pedal I tapped on the solenoid and it clicked in and moved again! I unhooked the new controller and put back in my old one and went and got a new solenoid and it is fixed! I also noticed the cart moved faster and had more torque with the other controller box so I bought it too and the cart is back up running better than ever!
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Unread 08-21-2011, 10:36 AM   #9
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Default Re: 92 DS Stopped Moving Forward or Reverse

thanks for the update...........................................8 )
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Unread 08-21-2011, 11:13 AM   #10
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Default Re: 92 DS Stopped Moving Forward or Reverse

Quote:
Originally Posted by j_verscheure View Post
Club Car is fixed and working better than ever! I just want to say I jacked up the cart and jumped out the two large posts on the solenoid! Nothing happened so I counted out the solenoid which was the wrong thing to do!
I than moved on and after checking and testing every wire and cable there is I figured it was the PMC Controler box. Lucky for me Thoroughbred Custom Golf Carts of Englewood (Which I will add is Great Place to go the owner and staff are Curtious and Very Knowledgeable) had a used controller box and let me try it before I bought it for $75.00! I brought it home and installed it put the solenoid back in hooked up the batteries. The cart moved when I hit the pedal but cut right out again and would not move! However this time I had the seat off and when it kicked out I heard a loud click in the solenoid!. I took my channel lock plyers and while depressing the pedal I tapped on the solenoid and it clicked in and moved again! I unhooked the new controller and put back in my old one and went and got a new solenoid and it is fixed! I also noticed the cart moved faster and had more torque with the other controller box so I bought it too and the cart is back up running better than ever!
A solenoid bypass which consists of a battery cable connecting the 2 large posts essentially takes the solenoid out of the power supply loop. If the solenoid was not making the connection internally then this should have made the cart run. A new solenoid which makes the connection makes the cart run? I'm confused.
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