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Unread 07-12-2013, 04:43 PM   #1
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Question HELP! 95 48 volt Club Car not moving

Working on a 1995 48 volt Club Car series cart. It has all new 8 volt batteries and cables and a brand new 48 volt solenoid. The cart sat for a long time, but ran when parked. When we tried to get it to move we at first assumed batteries, so we put on new ones. Then we didn't hear a click when pressing the gas, so we put on a solenoid. Also followed the instructions to reset the OBC from the stickies on here. Here's the stage we're at now: the cart acts as if it wants to move when you press the gas, and you can hear the controller whine for about a second but then it stops and the cart seems to quit trying to move. Also, even though the cart acts like it wants to move I can't hear the solenoid click. The charger will not kick on when plugged into the cart either, but it does run when plugged into another 48 volt cart. Any help is appreciated!
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Unread 07-12-2013, 05:29 PM   #2
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Default Re: HELP! 95 48 volt Club Car not moving

Sounds like more than 1 issue.

Check carefully to see the battery install was completed properly, no loose wires hanging?

48v+ present at the battery pack mains?

Concentrate on getting the solenoid to consistently click when you try to go.

The solenoid must have + and - present at the 2 small terminals in order to 'click' which one are you missing? The + or the minus
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Unread 07-12-2013, 10:36 PM   #3
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Default Re: HELP! 95 48 volt Club Car not moving

Quote:
Originally Posted by scottyb View Post
Sounds like more than 1 issue.

Check carefully to see the battery install was completed properly, no loose wires hanging?

48v+ present at the battery pack mains?

Concentrate on getting the solenoid to consistently click when you try to go.

The solenoid must have + and - present at the 2 small terminals in order to 'click' which one are you missing? The + or the minus
Scotty, thanks for the quick reply. I'm positive the batteries are in right, I've checked more than a few times thinking I might've screwed up. Also, no wires hanging or loose, checked that also.

I get 50.0 volts at the main terminals of the pack.

Not so sure about solenoid wiring. I wired the new one up EXACTLY like the old one came off and put the resistors from the old one on the new one, but someone could have messed with the wiring on the old one before me. Not sure of the proper wiring for the solenoid on this particular cart, as I've mostly only worked on 36 volt carts. Perhaps this may help. On the terminals of the solenoid I have:

Back small terminal - 1 small yellow wire (going toward back)
Front small terminal - 1 small red wire and 1 small white wire w/black stripe (coming out of grey main sheath, I think from the front)
P.S. large terminal - large red wire (main + lead from battery pack) and 2 small red wires and 1 small green wire (coming from main grey sheath, I think from the rear)
D.S. large terminal - large yellow wire (going to controller)

Is this correct?
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Unread 07-13-2013, 05:31 AM   #4
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Default Re: HELP! 95 48 volt Club Car not moving

Is the cart a vglide or pot next to the pedal on underside of frame?
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Unread 07-13-2013, 08:43 AM   #5
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Default Re: HELP! 95 48 volt Club Car not moving

Quote:
Originally Posted by sunoco View Post
Is the cart a vglide or pot next to the pedal on underside of frame?
No v-glide, it has a box next to the pedal on the underside of frame.
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Unread 07-13-2013, 12:27 PM   #6
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Default Re: HELP! 95 48 volt Club Car not moving

I've checked more things today and still the same problem. All of the microswitches are plugged in, the M.S. by the gas pedal under the cart is working, as well as the key switch. All of the wiring is correct on the solenoid and the rest of the cart, per the 1995 service manual that I have downloaded. I am thinking possibly a bad OBC or controller, but have no idea which or how to test for this on this cart. Please help!
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Unread 07-13-2013, 02:38 PM   #7
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Default Re: HELP! 95 48 volt Club Car not moving

A breakthrough, I think...

I jumped the solenoid across the two large posts and the cart will run. Tried another solenoid and another set of resistor and diodes and still getting the same problem of the cart not moving. The resistor gets very hot, so the cart "nudging" forward at first is the resistor letting voltage through I think. The problem has to be in the wires going to the small posts and not making the solenoid click like scottyb said, though I have no idea about the + and - that was mentioned. Any advice on how to test these wires to see if they are working/ thoughts on something else that could cause this would be really appreciated.

EDIT: cart will only run forward with the solenoid jumped, but not in reverse

Last edited by 93yellowclubcar; 07-13-2013 at 02:43 PM.. Reason: added info
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