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Unread 01-26-2014, 08:17 PM   #1
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Question 81 DS CC - Fried F/R Switch?

My CC(Serial is A8132 XXXXX) has more torque/power in reverse than forward. It will spin the tires on dry unfinished concrete in reverse, but forward seems anemic in comparison.

I read several posts here that said the 18/36v leads may have been reversed. I reversed the white and black legs on the F/R switch and nothing. Tried both directions. I returned it to the previous places. NOTHING in either direction. Solenoids are not clicking at all. Did I fry something or have a loose connection somewhere?

I checked the two wires on the F/R microswitch, F/R white, F/R black and the buzzer. These were the only ones I touched.

The F/R switch on the 81-83 DS diagram does not look anything like mine. I am confused as to why mine is different.

I have three red wires on the passenger side of the F/R switch. Two of them are going to Battery #1 and one goes to the bottom-driver's side of the motor terminal. Two wires, one white and one black are on the moving portion of the F/R switch. White is on driver's side and goes to the resistor coil, solenoid #5. Black is passenger's side of the F/R switch and goes to the bottom-passenger's side of the motor terminal. The top two terminals on the motor have white coming from the master solenoid to the passenger's side motor terminal. The other is black to the battery pack negative. It has a Hitachi motor.

What gives? Fried something?
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Unread 01-27-2014, 10:15 AM   #2
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Default Re: 81 DS CC - Fried F/R Switch?

I think a picture may assist us here, especially since you stated that the diagrams are not like your cart.
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Unread 01-27-2014, 11:09 PM   #3
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Default Re: 81 DS CC - Fried F/R Switch?

So, after a bit more looking, the PO had 36v going to forward and reverse. I ran it like this for several weeks without issue, other than reverse having more speed/power than forward.

I have moved the right red cable from the first battery to the fourth(counting left to right). See here for where it is attached:


Here is a closeup of the F/R switch:


Here is the battery wiring PRIOR to moving the reverse to 18v.


Here is the micro on the F/R switch:

The blue goes to the ignition, I think. The yellow goes to the speed control box.
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Unread 01-27-2014, 11:15 PM   #4
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Default Re: 81 DS CC - Fried F/R Switch?

I want to do a body-off tear down and replace all the wires, solenoids, switches, etc.

I don't have a fortune in it and the batteries are new. I think I have a good base from which to build though.
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Unread 01-27-2014, 11:18 PM   #5
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Default Re: 81 DS CC - Fried F/R Switch?

I don't know what might be fried, I will say that I had an old 5 solenoid cart once that I purposely hooked up 36 volt reverse on. I backed up a lot - wanted the extra power and not to be using off half my batteries for reverse. It would always burn rubber in reverse on dry pavement, but rarely in forward would it do this. Why? I have no clue really because the gearing is the same, but it sure enough would take off better in reverse. My EZGO 3 wheeler that I still have is the same way...

Someone is bound to be along shortly with an idea on what could be keeping you from moving.
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Unread 01-27-2014, 11:28 PM   #6
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Default

Yep leaves double black marks in reverse. Not a chance going forward. I thought the 18/36v might have been reversed. Still not sure what I broke.

I reversed the white and black, tapped the throttle in F/R with no movement. Switched yellow/blue on micro and tapped the throttle in F/R, nothing. I put it all back and no va!



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Unread 01-27-2014, 11:33 PM   #7
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Default Re: 81 DS CC - Fried F/R Switch?

Presuming correct voltage both directions you are encountering a normal winding function of the motor. All motors have a directional preference and Club car diff's are backwards to the preferred rotation. Turned the diff backwards on my dragster and picked up 4 mph with much better initial acceleration. It is possible to re-position the brush holder to tune the preference but the armature windings can't be altered without an expensive rewind. Not worth the trouble.
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Unread 01-27-2014, 11:45 PM   #8
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Yikes! Flipping the diff or rewinding the motor sounds like no fun.

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Unread 01-28-2014, 12:02 PM   #9
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Default Re: 81 DS CC - Fried F/R Switch?

Looking at your first photo, you have a badly burned cable and a very corroded cable at the battery connection. This will definitely hurt your speed and power! I would also put your forward speed cable on the battery first, as it will be the one used most of the time. We have a 91 DS that is also a bit more "juicy" in reverse too. That is normal for these carts when you have 36V to both forward and reverse.
As far as the no go, check that one solenoid small terminal is connected to B- through the V-Glide micro switch, and the other small terminal is connected to the F-R switch micro, which is connected to B+ through the key switch. You probably have a bad micro switch either in the V-Glide or on the F-R switch.

Edit: This post will help with wiring. Look at page#2 post#12
Electric Club Car wiring diagrams
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Unread 02-02-2014, 12:28 AM   #10
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Wink Re: 81 DS CC - Fried F/R Switch?

Quote:
Originally Posted by simple man View Post
Looking at your first photo, you have a badly burned cable and a very corroded cable at the battery connection. This will definitely hurt your speed and power! I would also put your forward speed cable on the battery first, as it will be the one used most of the time. We have a 91 DS that is also a bit more "juicy" in reverse too. That is normal for these carts when you have 36V to both forward and reverse.
As far as the no go, check that one solenoid small terminal is connected to B- through the V-Glide micro switch, and the other small terminal is connected to the F-R switch micro, which is connected to B+ through the key switch. You probably have a bad micro switch either in the V-Glide or on the F-R switch.

Edit: This post will help with wiring. Look at page#2 post#12
Electric Club Car wiring diagrams
V-Glide? What fancypants talk is this. Up until I replaced the brake shoes, we had to Fred-Flintstone this dinosaur to a stop! I have a speed switch assembly!

Post #4 here, right:
Electric Club Car wiring diagrams
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