Solenoid Bypass?

davejam · 07-07-2008, 05:03 PM

I have a 1996 Club Car DS 48v. Last night my car began to only lurch forward (or backward) when I depressed the accelerator. After a bit of tracing with my trusty voltmeter, I determined that the solenoid was not closing. To verify, I bypassed the solenoid by simply connecting both large cables to one post. With the solenoid bypassed, the car functions normally. My question is, what would the long term effects be of leaving the bypass in place.

On another note, before the solenoid failed, my charger was kicking on and off about every 30 seconds. The voltmeter connected to the batteries shows right around 50 volts. Could these be related?

Thanks

roady89 · 07-08-2008, 06:08 PM

Your controller will be on all the time. I would get a solenoid as soon as possible. Do you know if you have an OBC? I would a least unhook the bypass while charging so you dont cook something.

davejam · 07-08-2008, 06:40 PM

Thanks! I returned it to the normal wiring as I will not using it for a couple of weeks. In the mean time I will order a new solenoid. Any idea why the charger kicks on and off every 30 seconds or so? (I did not leave the charger connected since I'm not sure if there is an issue there.)

Thanks again
DCC

roady89 · 07-08-2008, 06:52 PM

I think what is happening is...the OBC is telling the charger to come on....but the OBC is also supposed to shut off the controller as a safety feature so you don't take off with the charger plug still hooked up...well with your bypass the controller is always on...the OBC cant shut the controller down so its freaking out.....Anyway...something like that, who knows. Thats my best guess. LOL!

davejam · 07-08-2008, 06:55 PM

heh - shutting on and off in the normal wiring mode. With the bypass, the charger does not come on at all. In any event... I have disconnected the charger until I can spend some time troubleshooting it. I ordered a shop manual so that should help. Thanks again.

roady89 · 07-08-2008, 06:58 PM

Darn shame there are no Club Car manuals in PDF format on the net.

rusty · 07-08-2008, 08:29 PM

Welcome to the forum davejam.......................

davejam · 07-08-2008, 08:38 PM

Thanks! Seems like a good one. Lots of great information.

07-07-2008, 05:03 PM	#1
davejam Not Yet Wild Join Date: Jul 2008 Location: Ocean City MD Posts: 4	Solenoid Bypass? I have a 1996 Club Car DS 48v. Last night my car began to only lurch forward (or backward) when I depressed the accelerator. After a bit of tracing with my trusty voltmeter, I determined that the solenoid was not closing. To verify, I bypassed the solenoid by simply connecting both large cables to one post. With the solenoid bypassed, the car functions normally. My question is, what would the long term effects be of leaving the bypass in place. On another note, before the solenoid failed, my charger was kicking on and off about every 30 seconds. The voltmeter connected to the batteries shows right around 50 volts. Could these be related? Thanks

07-08-2008, 06:08 PM	#2
roady89 nimda Join Date: Jun 2007 Posts: 13,022	Re: Solenoid Bypass? Your controller will be on all the time. I would get a solenoid as soon as possible. Do you know if you have an OBC? I would a least unhook the bypass while charging so you dont cook something.
roady89 nimda Join Date: Jun 2007 Posts: 13,022

07-08-2008, 06:40 PM	#3
davejam Not Yet Wild Join Date: Jul 2008 Location: Ocean City MD Posts: 4	Re: Solenoid Bypass? Thanks! I returned it to the normal wiring as I will not using it for a couple of weeks. In the mean time I will order a new solenoid. Any idea why the charger kicks on and off every 30 seconds or so? (I did not leave the charger connected since I'm not sure if there is an issue there.) Thanks again DCC

07-08-2008, 06:52 PM	#4
roady89 nimda Join Date: Jun 2007 Posts: 13,022	Re: Solenoid Bypass? I think what is happening is...the OBC is telling the charger to come on....but the OBC is also supposed to shut off the controller as a safety feature so you don't take off with the charger plug still hooked up...well with your bypass the controller is always on...the OBC cant shut the controller down so its freaking out.....Anyway...something like that, who knows. Thats my best guess. LOL!
roady89 nimda Join Date: Jun 2007 Posts: 13,022

07-08-2008, 06:55 PM	#5
davejam Not Yet Wild Join Date: Jul 2008 Location: Ocean City MD Posts: 4	Re: Solenoid Bypass? heh - shutting on and off in the normal wiring mode. With the bypass, the charger does not come on at all. In any event... I have disconnected the charger until I can spend some time troubleshooting it. I ordered a shop manual so that should help. Thanks again.

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07-08-2008, 06:58 PM	#6
roady89 nimda Join Date: Jun 2007 Posts: 13,022	Re: Solenoid Bypass? Darn shame there are no Club Car manuals in PDF format on the net.
roady89 nimda Join Date: Jun 2007 Posts: 13,022

07-08-2008, 08:29 PM	#7
rusty Golf Cart Photographer Join Date: Jan 2007 Location: Wichita Falls Texas - My Ride 2010 Club Car Posts: 6,236	Re: Solenoid Bypass? Welcome to the forum davejam.......................

07-08-2008, 08:38 PM	#8
davejam Not Yet Wild Join Date: Jul 2008 Location: Ocean City MD Posts: 4	Re: Solenoid Bypass? Thanks! Seems like a good one. Lots of great information.

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