81 club car repair help

stugotz

Hello all. Just signed up and need advice on a new project i bought at auction.

This cart is the older resistor version and I dont see the V glide part so its real basic.

Cart did not run when I purchased it and it didnt have any batteries. I now have 6 fully charged 6V batteries installed and get approx 40V across them and same voltage to the F&R switch. This cart didnt have a keyswitch in it and no wires behind the panel so I think someone bypassed it if it existed.

My question is what to check first and where do I go from here.

BGW

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scottyb

That's a big question!

1. inspect the cart wiring for damage. Rats and corrosion can stop a connection. Repair any obvious damage.
2. check pack voltage. Check solenoid activation circuit voltage. (big step here. solenoid must click when you press the gas.)
In your case there are 5 solenoids and 5 micro switches in a sm box at the end of the gas peddle linkage.

Go to the top of this section and print out all the info/diagrams pertaining to the 5 solenoid drive system

stugotz

Thanks for the reply...I found the wiring diagram you mentioned and I will start there . The coil packs are not clicking when stepping on the gas pedal. Wiring is not damaged and looks good all around the cart . Battery pack voltage is approx 40V +/- and I can get that up to the FR switch. What Im hoping to find is a powerflow chart or troubleshooting checklist ....anything like that exist?

jdunmyer

Stugotz,
I have a 1979 CC that had the same setup as yours; I've changed it to a Curtis controller, but that's another story.

Mine had 2 of the 5 solenoids missing when I got it, probably one reason it was at the auction. When I disassembled it, I found 2 of the 3 remaining to be bad, they clicked, but didn't pass any power. What I'm saying is, check them carefully, and assume nothing.

If you get NO clicks, you're not getting power to the microswitch stack on the accelerator pedal. (missing keyswitch?) Besides the keyswitch and the microswitch, there's another microswitch or 2 on the F/R switch. This is to prevent switching that high-power thing while under load. I'm not sure which order the power is wired, but the diagram should help you out.

Basically, the power goes through the keyswitch, the accelerator, and the F/R switch to the first solenoid, which is the LH one on the bracket. (as viewed from behind the cart, not the way you'd look at it from the front.) As you continue to press down further on the accelerator, more solenoids are energized, shorting out those big resistors to put more power to the motor. However, you need to get the first one to energize.

If the wiring is in good shape, it's probably something pretty simple.

stugotz

Update: Cart still wont move

- found the previous owners attempt at a bypass to the keyswitch wires and I fixed that so it now sends power through the keyswitch wiring via a hidden switch he installed.

- I wasnt hearing the pedal box microswitches clicking all 5 clicks..only heard 4 clicks. Took it apart and found one microswitch stuck. Replaced the bad microswitch and now with that fixed I can get the main solenoid on the drivers side to click and actuate when depressing the go pedal.

- As said above the #1 main solenoid now actuates/ clicks but #2 and 3 dont. I can hear and feel 1,4 and 5 solenoids working. Cart still wont move even if I jump the main solenoid terminals.

-Im having trouble understanding the FR switch theory...is it supposed to send voltage or ground signal to the last solenoid. mine is sending a ground signal to the 5th solenoid.

-Also I have one red 4gauge wire that runs from the side of the FR switch to the motor...is that wire supposed to have power at any time? Im not seeing any voltage to that wire in F-R or at any time the go pedal is pushed.

Im thinking I have issues with my FR switch as well as the #2 &#3 solenoids mentioned previously.

Any input is appreciated.

scottyb

Replace the 2 bad solenoids and the F&R ... It's an old cart and those parts are probably pretty worn.

stugotz

Thanks Scotty!