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Unread 03-27-2014, 10:23 AM   #1
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Join Date: Aug 2010
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Default 97 Club Car DS won’t run or charge – Issue with Controller, Charger, or both??

Ok. Here is the rundown on my set up.
  • 1997 Club Car DS Series Cart
  • Lifted
  • 6 - 8 Volt Trojan T-875 Batteries - 3 yrs old & well maintained
  • 4 ga cables throughout - All tight & no corrosion
  • HD Solenoid & F/R switch (Lever)
  • GE Beast Motor
  • Had a Logisystems 700amp Controller - Just replaced it with a GE 500amp Controller (More detail on this below)
  • MCOR Conversion
  • Currently have a jumper from the (-) battery post (the one that runs through the OBC) to the small post on the solenoid due to previous issues in the past. I've had this in place for two years and cart has run without fail.



The Issue

Cart had been running great with no issues. Plugged it up to charge as usual. Checked it the next morning on my way out to work and the charging had “finished” but I noticed that the battery meter that I have installed in the dash was showing two or three bars short of a full charge which I though was weird. In the past the meter has always showed full charge after a charging cycle.

Got home from work and hopped on the cart for a ride and cart would not move at all. No forward or reverse. Solenoid clicked when the pedal was pressed as usual but no movement. Also tried to plug in the charger and charger would not kick on to charge. It is like something happened during the last charge that caused the charger to cut out prior to completing a full charge and whatever happened also caused the cart not to run anymore. So at this point the cart won't charge or run. So I started running some tests to try and pinpoint the problem.


Testing Preformed
  • Ran jumper from large (+) to large (-) posts on solenoid - Still no go. So solenoid is ok.
  • Checked pack voltage - Just shy of 51 volts - All Good
  • Tried to load test pack - Key on & F/R lever in forward but not change in pack voltage as pedal was pressed
  • Tested micro switch in MCOR with paperclip - All Good
  • Tested MCOR input to controller - 5 ohms with no pedal and reduced to 0 ohms as pedal was pressed - All Good
  • Tedted controller output to motor *** which is where I found the issue*** With key on and F/R in forward connected multimeter leads to M- and B- on controller. With pedal up the reading was 35 to 36 volts. Pressed pedal solenoid engaged (clicked) voltage jumps to full pack voltage of 50 to 51 volts (normal). As pedal was pressed to floor voltage did not decreased as it is supposed to, just stayed at 50 to 51 volts. So bad controller right???


So apparently my Logisystem controller had gone bad. Ordered a new GE controller and installed it yesterday afternoon. After install cart was working. Took it for a quick drive just to test it (literally 75 yards) and everything was working fine. Parked the cart, put it in neutral, and turned the key off. I did not try the charger at this point.

Came back out about two hours later for another ride and now the cart WOULD NOT WORK AGAIN! Tried plugging in the charger just to see if it would work and it would not. I then tested the controller output to the motor, as I did the previous controller, and got the same result as before. Voltage did not drop as the pedal was pressed. So is this brand new controller now bad also?!? What could be causing this to happen?!?

I am out of ideas and don’t know where to go from here. And as I’m sure you know controller ain’t cheap. Anyone got any ideas as to what could be causing all of this?!?
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Unread 03-27-2014, 10:36 AM   #2
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Default Re: 97 Club Car DS won’t run or charge – Issue with Controller, Charger, or both??

Does the solenoid click when you try to go?

Is there 51v at controller pin #1 when you try to go?
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Unread 03-27-2014, 10:43 AM   #3
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Default Re: 97 Club Car DS won’t run or charge – Issue with Controller, Charger, or both??

Yes solenoid does click when pedal is pressed. And yes there is 51v at controller pin #1 when pedal is pressed and solenoid is engaged.
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Unread 03-27-2014, 12:13 PM   #4
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Default Re: 97 Club Car DS won’t run or charge – Issue with Controller, Charger, or both??

This is not a solution but an observation. I think things like this are bound to happen when you get carried away with the need for torque or speed.
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Unread 03-27-2014, 12:50 PM   #5
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Default Re: 97 Club Car DS won’t run or charge – Issue with Controller, Charger, or both??

I have made sure that this cart was set up correctly with all of the necessary components to support the upgrades that I have in place, which by the way are not "over the top" by any means. I have been running this set up for over three years now without any problem. Then one day the controller goes out. Ok, that happens. So I replace it with a brand new controller and it goes out (or seems to) after one use?? While I appreciate your opinion, I'm pretty sure that me "getting carried away with my need for torque or speed" is not the root cause of this particular issue.

If there is any guidance that someone could give me with this I would greatly appreciate it.

While opinions are great and all, I’m pretty sure that they are not going to help me solve this problem.
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Unread 03-27-2014, 01:11 PM   #6
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Default Re: 97 Club Car DS won’t run or charge – Issue with Controller, Charger, or both??

"This is not a solution but an observation. I think things like this are bound to happen when you get carried away with the need for torque or speed." ????
jjance ? what the hell are you talking about? Bless your heart...

Steve
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Unread 03-27-2014, 01:13 PM   #7
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Default Re: 97 Club Car DS won’t run or charge – Issue with Controller, Charger, or both??

Ryan,

What is your battery pack readings?

Steve
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Unread 03-27-2014, 01:16 PM   #8
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Default Re: 97 Club Car DS won’t run or charge – Issue with Controller, Charger, or both??

Ryan

Sorry I see you measured 51 volts.

Steve
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Unread 03-27-2014, 02:26 PM   #9
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Default Re: 97 Club Car DS won’t run or charge – Issue with Controller, Charger, or both??

Yeah 51 volts. And that is with the pack only a little over 2/3 of the way charged. Or at least that is what the charge meter in the dash is indicating.

Oh and thanks for the support BTW!
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Unread 03-27-2014, 02:44 PM   #10
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Default Re: 97 Club Car DS won’t run or charge – Issue with Controller, Charger, or both??

Ryan,

Are you sure the controllers are bad? Is your battery packed saftey fused to the controller? I fried a ALLTRAX 650 last year when the Beast motor fried. Basically the motor came apart inside and would send all the juice through the cart. This smoked my controller. Obviously this isn't your issue. Have you double checked all your wiring? I know this may sound stupid but in the past I'v had ghost issues so I would just take everything apart and just carefully inspect? Can we bench test controllers?
Steve
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