96 Club Car - Wont move

95Superglide

Hi All,
I have a 1996 Club Car - series that just stopped working. One day it was fine, the next morning it wont move.
I've tried to comb through almost every post regarding this topic, and still cant figure out exactly what is the failure.

Batteries are less than a year old, (6) 8v Trojan T-875's - removed/cleaned all posts and cables.
Pack voltage = 51.4v - 51.3v with pedal down

Performed solenoid test - removed load side wire going to controller, also removed the resistor. measured voltage on load side of solenoid to (-) on #6 battery. Pedal up 0v -- Pedal down 51.4v - normal click in solenoid.

Measuring the controller from M- to B-
pedal up 51.2v - pedal down 46.6v

Measuring the pot from pin 3 and B- on controller
pedal up 700ohms - pedal down 14-16k ohms

No leads on motor are shorted to the case, all measurements were taken with the key on, and FR switch in F.

Any thoughts would certainly be appreciated. Thanks!

BGW

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93yellowclubcar

Try resetting the OBC, on my phone or I'd link it for you, but directions for it are in the stickies up top in this section.

Also, welcome to BGW!

95Superglide

Thanks!
I had already reset the OBC. my backup buzzer has been disconnected for a couple years. I went ahead and plugged it back it and re-performed the OBC reset, so I could hear it fade.. No Change, cart will just barely move a couple feet.

Are those resistances normal for a continuously variable pot?
I'm leaning to think that either the pot or the controller went bad, I just hate to start ordering random parts.

shadowman

What color is controller? If black I.d lean that way have you tried your charger since breakdown?if its acting up than OBC that year cart those symtons its one or the other.

scottyb

What!? WHO is this really? ... and what did you do with Tom ????

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95Superglide

Its black on the end?

93yellowclubcar

Shadowman! I don't think we've ever conversed on here, but man I learned a heck of a lot by reading your posts back in the day when I was just learning carts! Great to see you on here again!

cmar143

I think that cart has 3 pin potentiometer and the way to check it is with your DVM on ohms put one lead on the purple and one on yellow and as you press the gas pedal you should see your meter respond exactly to pedal movement without jumping around and stay between 0-5k. Under normal operation with DVM on volts and leads on B- and M- voltage should go from full pack with pedal up to 0 with pedal all the way down. If potentiometer checks out I would bet controller is bad

95Superglide

It does have the 3 pin connector from the pot, the yellow and purple, before i measured them at the controller, this time i opened the connector and measured 400 ohms with the pedal up and the same bouncing around 14-16k with the pedal all the way down.

On the controller this time it went from 52v(pedal up) to 47v(pedal down)

Are those pot numbers out of tolerance? And would that extra resistance cause the cart to not move?

Thanks!

cmar143

The resistance must be consistent with the movement of the pedal so if its bouncing around especially out of the 0-5k range that is your problem.