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Unread 10-09-2019, 05:19 PM   #1
Not Yet Wild
Harley Davidson
 
Join Date: Oct 2019
Location: Washington State
Posts: 4
Default 76 HD DE-40 electrical troubleshooting

Greetings. My electric golf cart dies after running about 150'. If I let it sit for 30 mins or so I can sometimes get it back to the shop. It's a 36 volt car, and meter says 37.7, so I think my batteries are ok. I have the manual and am trying to work my way through the troubleshooting but I'm confused as to how to test the solenoids (there are 3, F and R have 6 terminals, and B has 4 terminals. My key switch only has three positions, off, reverse, and forward. I do hear a loud click from the solenoids when I switch from off to R or off to F. Is there an easy routine for testing these solenoids while still in the car? I do have a digital multi-meter. I can't find any testing procedures for a 6 terminal solenoid on-line. Should I be hearing the loud click when I turn the key, or not until I step on the "gas" pedal? Thanks in advance for any tips or clues!
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Unread 10-09-2019, 06:10 PM   #2
Gone Wild
Mixed Breed
 
Join Date: May 2019
Location: Georgia
Posts: 363
Default Re: 76 HD DE-40 electrical troubleshooting

Many different ways to test on the cart. I will usually take off the 2 small activation wires, hook them to a meter & try to run cart, If you have voltage than you probably lost the solenoid. You can do this test on the 6 lugger also.
However go ahead and verify that your key switch is good...
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Unread 10-14-2019, 04:33 PM   #3
Not Yet Wild
Harley Davidson
 
Join Date: Oct 2019
Location: Washington State
Posts: 4
Default Re: 76 HD DE-40 electrical troubleshooting

I had previously taken the switch out of the car and tested it with the continuity tester, and it checked out ok. Now I have run through all of the electrical tests in the manual (solenoids, snap switch, brushes, motor) and everything checked out ok. Hooked the batteries back up this morning and the car runs great! So maybe it was a dirty or loose connection somewhere that I inadvertently fixed. I do have another issue with it that I will address in another post as it is unrelated (sticky "gas" pedal). Thank you LabRat!
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Unread 10-20-2019, 04:46 PM   #4
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Harley Davidson
 
Join Date: Aug 2009
Posts: 10,539
Default Re: 76 HD DE-40 electrical troubleshooting

Hi Laura-

I just came across your thread. Congrats on your sparky Harley. I own a '68 DE electric. We are in a special group, as most of these old Harleys are gassers. These electric carts have a fairly complex, possibly over-engineered drive system. Two years back, I actually did a poor man's solid state conversion on mine. If you want to check out the thread I put together on my cart, feel free to click the link in my signature below. Happy carting!
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