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Unread 10-10-2011, 12:06 PM   #41
Not Yet Wild
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Join Date: Oct 2011
Location: WI
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Default Re: 1996 48v Regen Module Issue

Hello Tom,
Test 1) With 49 volts applied to the input side of the solenoid, nothing would happen. No clicking from the solenoid either. Backup alarm would come on when Rocker selected to Reverse.
Test 2) I applied voltage to the output side (Yellow Cable) Real large spark. (picture shows the welding)
Test 3) With voltage applied directly to motor, tires would turn. Not real fast, but was jumping power from a second cart thru jumper cables.
Test 4) I attemped to test the solenoid. Checked continuty across the two small terminals and I had resistance. I assume this was the case since the small diode was in place. What did shock me was there is no ground on this solenoid (So I thought) The Positive side of the small terminal had one Blue wire. The other terminal had several small wires. I was thinking these were both positive. With cars, they sometimes ground thru the mounting plate. This C.C. solenoid is all plastic. Since the solenoid is screwed together, I decided to take it apart. After pulling the solder joint apart, I did learn that the negative side was on the side with all the small leads. Anyway, the solenoid is now junk.
We all know it's going to take some money to get this back running. It's just a matter in how much do I want to spend if there the potential I will get nothing out of it. The solenoid is simple. The Controller is another!
It was mentioned earlier, would a good dealer be able to test my contoller on a bench to see if that is truely the problem? It would be real nice to know.
Based on everyones experience, what else is there to go bad with this carts? Maybe my Pedal is bad... This could also be the problem correct??
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Unread 10-10-2011, 12:08 PM   #42
Not Yet Wild
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Default Re: 1996 48v Regen Module Issue

Solenoid Picture
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File Type: jpg solenoid.JPG (145.7 KB, 4 views)
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Unread 10-10-2011, 12:11 PM   #43
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Default Re: 1996 48v Regen Module Issue

BTW, I checked continuty from battery ground to the small terminal with several wires and there was nothing. Trigger - If you could get me a wiring schematic, that would be GREAT!!!
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Unread 10-10-2011, 12:17 PM   #44
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Default Re: 1996 48v Regen Module Issue

i don,t know about a dealer, some can but i don,t put all my trust in them...... but you should be able to send it to the manufacturer to have it tested...............i don,t trust testing solenoids with a meter as its not 100% .....there are guys who will argue this and thats ok but beleive me the voltage meter isn,t always right thats why i ask to manually jump the large post to see what happens.......you can use the other solenoid to do this just put it back when your done..............................................
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Unread 10-10-2011, 12:42 PM   #45
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Default Re: 1996 48v Regen Module Issue

Tom - Your saying to jump the two large post together with a screwdriver and see if I get movement? Will the other small leads on the terminal need to be connected? Are they actually grounds? Please review my picture from this morning. Thx
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Unread 10-10-2011, 12:56 PM   #46
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Default Re: 1996 48v Regen Module Issue

Pais54,...Send me a private message with your email address and I'll send you the schematic for the 1996. I did not realize that you had some old batteries. What have you done to test them to see if you could rejuvinate them enough to at least test the unit.

Also, when you took the old solenoid apart and the wires broke, are you able to clean the wires and connect them with a small crimp connection?

Also,..here is a link to a 48 volt solenoid on eBay, new in box for $18.

http://www.ebay.com/itm/GOLF-CART-CL...item1e66ff857b
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Unread 10-10-2011, 02:08 PM   #47
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Default Re: 1996 48v Regen Module Issue

Trigger - I'll send you a message in a bit for my email. Thanks on the solenoid. I did find some yestersday that were in this dollar range. I still need the diode across the small terminals correct?
The batteries are real bad. Since these have been in the Wisconsin winter weather for the last 2 years, the cases are split open. We knew these were junk when we swapped them from the 1999 cart.
I've been doing my trouble shooting by jumping 48 volts from my other Club Car. I should really swap the batteries over, but tend to use the cart on a daily basis.
Tim
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Unread 10-10-2011, 02:21 PM   #48
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Default Re: 1996 48v Regen Module Issue

Pais54,,... I just remembered that when I Upgraded my 1996 as I mentioned before I had to put in a new 500 amp controller, 4 Guage cables, high current solenoid, etc. So I just went out in the garage where I had stored the stock controller and sure enough I found the original Solenoid. So if you decide to buy the Controller I wil include the Solenoid for $15. I think the only thing you would need to do is find a dealer that is willing to sell you some 8 volt batteries that have been exchanged for a new set. Or just post a want on Craigslist in your area. There are all kinds of ways to proceed.
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Unread 10-10-2011, 04:06 PM   #49
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Default Re: 1996 48v Regen Module Issue

Trigger - This is some great information. Does your solenoid look like the one I have or is it the round version? I will need the diode across the two small terminals correct? This comes this way on my factory solenoid.
Thinking of batteries, is the year and month on the one terminal? I believe their is a code. Example: 'H3' Is the 8th month of 2003?? Please advise.
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Unread 10-26-2011, 12:03 AM   #50
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Default Re: 1996 48v Regen Module Issue

pais54,,... It has been awile and I never received any email. So I'm going to attach the simple schematic I have for the cart. I would caution you on testing any other solenoid since I think you blew the first one by not connecting thing right. If you get a 2nd hand or new solenoid, there will be 4 terminals. The two small terminals are the ones that "Energize" the solenoid and they are marked + and -. If it is a 48 volt solenoid that is what it will take just to energize it. YOu don't have to connect any other wires at all, especially the heavy duty large gauge cables as those are the ones that carry all of the amps. If you start with the +48 volt connect the ground lead to the - terminal, then just touch the +48 volt lead the the + terminal and you should hear the solenoid energize. You will know it is good.

If for some reason you have changed your mind and are dropping this issue, let me know as I will put the items up for sale.

http://www.buggiesgonewild.com/attac...1&d=1319601712

Wiring 950348vuv0.jpg
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File Type: jpg V-Glide950348vuv0.jpg (64.0 KB, 12 views)
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