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Unread 05-22-2014, 01:02 PM   #1
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Default 83 Club Car Forward/Reverse Issue

New Poster here (be gentle)

I have a '83 Club Car DS electric, that I purchased as a non-running Cart. It is a cart with the 5 solenoid system. After replacing micro switches, #1 and #2 solenoid along with another used F/R switch I realized the motor was bad. Motor is a Hitachi MT320-07 and was difficult to find but finally did from Bill at Luna Industries out of AZ.

Last night I bolted it back up and hooked juice to her and I was going forward quickly, but the F/R switch was set to reverse. And when I put the switch in forward I got nothing. Just the sounds of all microswitches firing off.

So, I switched the two cables on the motor that run down from the F/R switch and now she goes reverse while in reverse, but does nothing in forward. After playing a bit with the pedal and the cart if forward position I noticed smoke coming from the #1 solenoid cable that runs from the large terminal to the motor.

Question: Has anyone had this problem or know how to diagnosis? Looks as if the F/R switch is giving me juice, but maybe a bad switch or wire somewhere between solenoids. I have an ohmmeter and am open for suggestions.

Thanks,
Sean
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Unread 05-22-2014, 01:08 PM   #2
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Default Re: 83 Club Car Forward/Reverse Issue

This 5 solenoid resistor coil system has 5 micro switches in a box at the end of the gas peddle linkage ..... I hope this helps
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Unread 05-22-2014, 01:13 PM   #3
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Default Re: 83 Club Car Forward/Reverse Issue

Thanks Scotty for the response. The cart seems to cycle through all micro switches just fine. Problem is I am only getting Reverse, no forward. If I hold the pedal down while "forward" is selected the wire off the main solenoid that leads to the motor just smokes.

Also it is a 36V cart, forgot to add that in the opening post
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Unread 05-22-2014, 01:15 PM   #4
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Default Re: 83 Club Car Forward/Reverse Issue

These carts have a separate power feed for reverse that is hooked to the positive terminal of the #3 battery. Is yours there?
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Unread 05-22-2014, 01:22 PM   #5
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Default Re: 83 Club Car Forward/Reverse Issue

Yes the separate cable is hooked up. I believe it is hooked to the end battery though not #3.

Is that Ok?
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Unread 05-22-2014, 01:26 PM   #6
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Default Re: 83 Club Car Forward/Reverse Issue

Yes, that just gives you a full 36 volts in reverse instead of 18. Just so it's on a positive terminal.
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Unread 05-22-2014, 01:35 PM   #7
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Default Re: 83 Club Car Forward/Reverse Issue

So when I initially hooked up the motor and crossed the two wires coming from the F/R , the cart would move forward like it should it was just doing it in the reverse setting. At that time the cart did not move at all when "forward" was selected.

Seems like the Reverse side of the F/R Switch is doing what it should, but the Forward side is not
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Unread 05-22-2014, 01:45 PM   #8
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Default Re: 83 Club Car Forward/Reverse Issue

It does. Has all the symptoms of a fried F/R switch or possibly some funky wiring on the F/R switch. I've looked, but there's no diagram of the F/R wiring for the 83 up in the wiring "stickies" section. Maybe someone who has that diagram (Where are you Crash??) will be along shortly.
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Unread 05-22-2014, 01:53 PM   #9
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Default Re: 83 Club Car Forward/Reverse Issue

Thanks for all your help YellowCar. I thought F/R switch was the problem until I noticed the #1 solenoid was getting juice as that wire coming off it started smoking after holding down the pedal.

Now I'm thinking maybe for some reason the #2 solenoid is not getting the juice it needs to move the tires.....I'll wait to see what some others have to say
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Unread 05-22-2014, 05:32 PM   #10
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Default Re: 83 Club Car Forward/Reverse Issue

from CTD....
Attached Images
File Type: png 84f-rswitch_zps99070bd3.png (90.8 KB, 0 views)
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