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Unread 03-21-2013, 09:41 AM   #1
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Default 1994 Clubcar DS wiring route/problem question

Hello,

Cart quit moving while driving. Im thinking it is the solenoid. It is the 36 volt system and is the controller model. With the key on and the pedal pushed down I get no voltage out of the side of the solenoid that runs to the controller. The other side has 27 volts that is coming straight from on of the batteries. My question is this:
From the point when you turn on the key, what is ahead of the solenoid ? Maybe its not the solenoid at all. Is there a surefire way to test the solenoid to see if thats it or not ? Thanks, Erik
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Unread 03-21-2013, 10:20 AM   #2
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Default Re: 1994 Clubcar DS wiring route/problem question

The solenoid has to be activated to make contact across the 2 large terminals. The small terminals are the activation circuit. When + is applied to one small terminal and - is applied to the other small terminal the solenoid is energized and the contact is made across the large terminals.

The first test is to see if your activation circuit is complete at the small terminals when you press the gas (key on + in gear) If not check the F&R ms and the key switch and the V glide ms.(micro switch)
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Unread 03-21-2013, 10:27 AM   #3
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Default Re: 1994 Clubcar DS wiring route/problem question

Thanks! I will try that. Question, what am I looking for ? volts, or continuity, etc ?
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Unread 03-21-2013, 10:36 AM   #4
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Default Re: 1994 Clubcar DS wiring route/problem question

The solenoid activation circuit requires pack voltage. 36v in your case. Not 27v as that may not be enough to activate the coil.
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Unread 03-22-2013, 07:53 AM   #5
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Default Re: 1994 Clubcar DS wiring route/problem question

with the key on , the selector in forward and my foot on the pedal, i have 37 volts on the 2 small posts on the solenoid. I then checked the large post coming in and it has 27 volts on it and 27 volts on the other large post going to the controller. However, with my volt meter set on continuity, I checked the 2 small posts and dont get any. Im thinking that the wire is broke inside ? Thanks again for all your help. Youve gotten me this far!
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Unread 03-22-2013, 08:10 AM   #6
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Default Re: 1994 Clubcar DS wiring route/problem question

. . . I believe with battery pack disconnected and all wires removed from solenoid, VOM should have no continuity between 2 small terminals . . . if it showed continuity, solenoid would need replacement . . .

. . . if this is not correct info, someone will correct me . . .
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Unread 03-22-2013, 09:22 AM   #7
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Default Re: 1994 Clubcar DS wiring route/problem question

Test the solenoid activation for voltage not continuity. You should have 36v minimum between the 2 small posts when the peddle is pressed. You should have positive 36v minimum at the battery side of the solenoid (large post) all the time and Positive 36v at the controller side (large post) when the gas peddle is depressed. You must remove the resistor from the large posts for this test
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Unread 03-22-2013, 09:39 AM   #8
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Default Re: 1994 Clubcar DS wiring route/problem question

thanks. I have 37 v between the 2 small posts but only 27 v on the large post wit the resistor removed. hmm....
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Unread 03-22-2013, 09:51 AM   #9
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Default Re: 1994 Clubcar DS wiring route/problem question

Bad cable or connection?
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Unread 03-22-2013, 08:57 PM   #10
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Default Re: 1994 Clubcar DS wiring route/problem question

well, i was looking at a buggiesunlimited trouble shooting guide and i have 37 volts on the big terminal of the solenoid that goes to the controller. It said to undo the cable going to the controller and undo the resistor, which i did. Now I wonder how to test the controller. I was surprised to see a reman sticker on the controller! This could be bad.......
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