Another DS Not Moving

OleTimer

I have an old 48 volt DS with a high speed motor and 650 watt controller. I have also added heavy duty F/R switch, throttle potentiometer and solenoid. The cables #2 welding wire. The batteries are up and the cart generally runs good. The problem is that from time to time it just won't run in forward or reverse. I can hear the solenoid clicking when I step on the pedal. There seems to be no rhyme or reason when it doesn't run. It is usually after it has been run and turned off for a while. Then it is turned on and refuses to move. Thirty minutes to an hour later it will run just fine.

Any thoughts on what the problem might be? I am running out of fixes

BGW

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RidgeviewGolf

I have been working on my situation, sounds like yours. I found a wiring issue on my ON/OFF switch. However, I am thinking my wiring has a pinch somewhere. For now, it is moving, but I am thinking about getting a new wiring harness anyway.

For mine, I had to put the ORANGE and GREEN wires on my top post and BLUE on the right post (as sitting in the cart). This wiring sequence matches a cart that is running, so somehow, mine got switched.

OleTimer

Thanks Ridgeview, but that doesn't seem to be the solution. My wiring is correct and I have a relatively new wiring harness. It has been running fine for 2 years. In the past I thought I solved the problem by replacing the resistor on the solenoid, but that didn't work this time. With all the people commenting on the problem, one would think that there would be a common solution. I am glad you got yours fixed.

OT

mldavey

I have been having the same problem the same way you described.
My cart is a 2001 ds with all 2 gauge wiring, a alltrax 500amp controller.
My cart was working fine for about 3 years and then after a long sit (say about 8 hours) it will not go. A half hour latter away we go. It may stop sometimes running down the road, or not.
With the altrax controller it has a light that flashes to tell you the throttle input configuration, which is good in my case.
I have change the solenoid, but still no good, next I am going to test the potentiometer and see.
I will try to keep you posted. mike

OleTimer

Thanks ML
I have just put my cart up until the weather gets a little cooler (98 today). I will be interested to hear what you find out. It is a bitch to trouble shoot, as all of a sudden it will start working. Whatever the cause is, it is intermittent. Last year when I had the problem and thought I solved it. I replaced all the major components, solenoid, potentiometer, F/R switch with "heavy duty" versions. the latest fix was a burnt out resistor on the solenoid. Nothing seems to fix it for long
Randy

OleTimer

This problem continues to exist. It just runs when it wants to. I have replaced everything but the controller. The voltage on both sides of the solenoid is 54 volts. I am running out of ideas. Anyone have any suggestions?

smokey tennis shoe

what year of cart is it? Does it have a v-glide?

scottyb

Simple rule here, if the solenoid refuses to click the trouble is in the solenoid activation circuit or (rarely) the solenoid itself. This system is a series of switches and small wires. check keyswitch, F&R micro switch, V glide or MCOR micro switch and small wires to solenoid connection. When + and - are at the the 2 small posts the solenoid MUST click closed. (**don't let a resistor fool you into thinking there is 48 on both sides of the solenoid.)

If the solenoid clicks and cart does not go the trouble is in the high amperage side of the system. This includes the solenoid (contact between large posts, see **), the control (it needs a throttle signal to pass amperage!) the cables (every stinking one of em needs a tug & twist test as well as a visual for corrosion), The F&R switch (test for continuity in F and R) and the motor (roll the cart a foot and see if it goes? )

Hope this helps, & gives you some place to look with it when it wont go.

OleTimer

Let me start from the beginning:
I have a 1997 DS
It has been lifted -Jakes
Tires are 22 x 11-10
It has a BU-700 controller and BU motor package
All the cables are #2 welding lead
It also has a heavy duty solenoid and heavy duty F/R switch.The batteries are charged.
I recently replaced the key switch
For the past year plus, the cart will run some days and others not. When it runs, it runs well. It will often just shut down and then an hour later it will run again.
The solenoid clicks when the pedal is pressed. The voltage is 52 vdc on both sides of the solenoid with the resistor removed.

Sergio

Are You sure the solenoid clicks when the cart is having the problem?

The burn out resistor could be an indication the OBC is not providing the negative to the solenoid coil, which would cause excessive current on the pre-charge resistor. Under normal conditions there is very little current on the pre-charge resistor to cause it to burn.

If the solenoid does click when the cart does not run then I would look at the half-speed micro switch.