94 CC Series - motionless

MaxGyver

Hi all,

I've read many postings, but have not found an answer that fits or works.

PROBLEM: No Power to motor forward and reverse. (unless I jump solenoid)

The BASICS:
1994 Series Club Cart - batteries test good (38 VDC)

Removed Solenoid which tested OK (but I'd love to have a word with the engineer that jammed the thing into a corner!)

Tested diode and it is OPEN - not working <<< will this stop all power??

Tested Resistor and value was right at 250 Ohm

Any ideas would be VERY appreciated - I'm pretty new at working on carts.


Many Thanks, Max

BGW

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scottyb

I'm with you on that engineer... they should make him change motors, controllers, and solenoids all day
Your problem lies in the solenoid activation circuit. When you say open diode, you mean it will test the same as a piece of wire?
If yes, the short caused by this has probably fried the activation circuit micro switch or switches. One on the F&R and another one in the V-glide. Check those out... leave the diode off for now, replace it when you get running.

MaxGyver

Scotty,

What I meant on the diode was that it no longer directs (like a switch in the off position).
I just ran a meter across the micro switches on the F/R and you WIN the prize - there are 3 together and the one closest to the seat is showing ZERO in any position plus there is no "snap" sound as I open and close it.

So that I do not screw this up by replacing parts I don't need, can it be so simple as just replace the diode and switch? Would one of these going out burn out the other?

Let me know what you think. Thanks

scottyb

Yes, It could.
Remove the diode and remove the 2 wires to the bad micro switch. Use a small piece of sheel metal or? and jumper the 2 small wires... the solenoid should activate like this if that's all it is...

MaxGyver

I'm in Oregon so it's 9PM here now, will give it a shot in the morning and let you know. Trust me, my fingers are crossed!! Thank you VERY much, we neophytes don't have a "Chilton" for these carts and it's tough getting reliable info. Back ASAP

89GatorClub

The micro switch could also be sticking, thump it, to try and free it up and then see if it operates correctly then. Sometimes trash can get in them and cause them to stick, if this does release it I would go ahead and buy one in case it isn't just trash inside the micro switch

Brushpup

You know...I broke a post off my F&R micro while re-doing a wire. The post was really weak and ready to go. Anyhow, I took the switch off and took it apart. It had three posts total so I took out the good one, flipped it over and had a good as new switch. Don't know if all of em are the same, but it worked for me.

MaxGyver

After 4 attempts to get out and try the fixes, I finally caught 30 minutes of dry!!! Another terrific day in Oregon - of course it's raining...

Reinstalled the solenoid and connected as (ScottyB) instructed - no go, I have no voltage on an of the micro-switches that work off the F/R switch with key ON or OFF.

With key ON and jumping from the forward small lug of the solenoid to the power sourced large lug, the cart has F and R with throttle control. Will check power at the key switch as soon as the present storm blows past and I can work without getting soaked. Tis A BAD thing to play with wet tools and this much amperage :) Will post as I get reading and if anyone else has a thought, don't be shy.

BB ASAP

MaxGyver

OK Guys,

On the micro switches, I only have the 2 connector type on this cart.

I tried the metal bypass but it was a No Go (literally...lol) That same switch which has wht/blk and green wires going to it, is definitely not functioning.

I have power to the key, and traced the "blue wire" to where it is spliced and transitions to white.

When I tried jumping power to the solenoid the cart ran as it should, but am guessing this isn't healthy for the electronics and definitely with the Key out of the equation it leads to problems.

I tried to print a copy of the wiring diagram on the "Sticky" but it's too low in resolution to get the words to print clear enough to read. If anyone has a higher definition camera, it would be awesome to repost those diagrams.

So for sure now I have a diode which is giving no readings in either direction, a micro switch which is fried or broken - but am more concerned this might not be all. ScottyB...let's get a parts list going!

shadowman

does cart have a v-glide? if so have you looked at the microswitch in there? if not check it..............................