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Unread 09-01-2014, 08:48 AM   #11
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Default Re: 1982 DS battery drain

Quote:
Originally Posted by Cardiac69 View Post
CCfanatic: If I loosen the ground cable from the end battery, and touch/remove it from the battery post, the solenoid clicks. If it was "welded", why would it click? And even worse, what is sending power to it without the key on?

Mr. Golf: The key switch works fine. The cart still runs OK.
If you hear a solenoid click when the negative cable is removed, that means that solenoid is "deactivating" or "opening" when the voltage is removed. You have a switch or wiring problem that is holding that solenoid closed when the pack is connected.
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Unread 09-01-2014, 10:05 AM   #12
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Default Re: 1982 DS battery drain

A welded solenoid means that it is stuck in the closed position, and always drawing voltage. When you drive the cart, is it a gradual speed increase, or is it fast right away?
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Unread 09-01-2014, 04:45 PM   #13
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Default Re: 1982 DS battery drain

OK, Mrgolf is kind of on to something. The cart has power and runs fine whether the key is on OR OFF. The key switch itself is fine. No continuity when off, 0 resistance when on. What could have the power on all of the time? I do have the wiring diagram, but am not real good with them. I get by :).

93yellowclubcar: I have the 5-switch rebuild kit on order already. Those will all be changed when they arrive. (Backordered)

jjance: only 1 extra wire is going to the drivers side outer battery + and 1 ground wire to the other drivers side battery - (12 volt light hook up). The cart is 2 hours away at our campground. Pictures next weekend if need be.

I need to figure out what is energizing the cart and now is doing so without the key being on.

Thanks for all of the great minds coming together!
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Unread 09-01-2014, 05:03 PM   #14
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Default Re: 1982 DS battery drain

I think yellowclubcar is dead on about the micro switch engaging the solenoid. That is a switch staying closed when it should not.
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Unread 09-01-2014, 05:10 PM   #15
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Default Re: 1982 DS battery drain

Temporarily disconnect the two wires to the lights and see if the problem goes away. Especially if the negative is connected to the frame.
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Unread 09-01-2014, 07:56 PM   #16
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Default Re: 1982 DS battery drain

ccfanatic: it has different speeds depending on throttle position. Floor it and it goes fast, or with a light pedal, it will go slowly. But it seems like it has only 2 positions: slow and fast.

jjance, I will try that one. Easy to do (Next Friday when I go back out).

mrgolf, it was a microswitch, it would be like stepping on the gas (throttle) pedal. What is causing the cart to be energized with the key off?
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Unread 09-01-2014, 09:12 PM   #17
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Default Re: 1982 DS battery drain

It wouldn't be like stepping on the gas necessarily if it was that middle switch - the cart won't move until the master solenoid (driver's side in the bank) is activated. Still, I agree there's two problems here, one with why the second speed (middle) solenoid is hot all the time, and one with why the key isn't killing all power.
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Unread 09-01-2014, 09:48 PM   #18
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Default Re: 1982 DS battery drain

recheck wiring
key activates f/r limit switch
f/r limit switch (on f/r switch) energizes master solenoid giving power to the restorer solenoid group
as pedal is pushed each micro switch engages a solenoid
there is no way 3rd solenoid can get power all the time with out wiring being wrong



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Unread 09-02-2014, 03:37 PM   #19
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Default Re: 1982 DS battery drain

Crash test dummy, this started on its own. I came to the campground after being gone for 5 days and that's when I found the pack voltage @ 20volts. I always charge it before I leave for the week. Key was out, and no one has access to the cart. Charged it up, put the key in and drove it. Seemed fine, until it sat for a while and discharged on its own. What could have happened on its own to be causing this dang thing to stay energized?
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Unread 09-07-2014, 11:14 PM   #20
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Default Re: 1982 DS battery drain

Did some testing over the weekend, using crash test dummy's diagrams and the service manual. I am at a loss. I found out nothing. Key switch tests as it should in the service manual. Micro switches test correctly as in section 3-5 of the service manual. Even the solenoids tested properly. I'm stumped. Anyone want to buy a one-owner, only driven to church on Sundays by a little old lady, 1982 DS????????
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