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Electric Club Car Electric DS, and Precedent golf cars |
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Thread Tools | Display Modes |
05-07-2015, 06:06 PM | #1 |
Getting Wild
Join Date: Jul 2014
Location: South Carolina
Posts: 111
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97 Club Car - Won't Move - Solenoid Clicks - Resistor Question
97 Club Car DS 48v
Cart was working fine other than an intermittent rattle coming from the rear end - could be the motor brushes or something. Parked as normal and hasn't moved since a few weeks ago. Key ON - pedal is depressed - Solenoid clicks, but what happens if the resistor is bad and out of spec from Test Procedure 7.2? I originally suspected the controller since there was no power to the F&R switch. But once it was bench tested it was reported working fine. If I trace the wiring diagram - the RED wire from the solenoid goes to the Controller Pin #1 -- 48v -- assume this is the input voltage referred to in Test Procedure 10.3. Makes me suspect if the voltage is not passed correctly to the controller, it won't "turn-on" to send power to the F&R switch and the cart will do nothing as it's doing now. From the Service Manual I see the following: Solenoid 1) Loose wires. Figure 20-2 or 20-3,Page 20-3 or 20-4 2) Failed contacts. Test Procedure 7 Test Procedure 7 - Solenoid Contacts (Power Off): As stated in WARNING above, follow procedures exactly. - REMOVE THE KEY. - PUT THE FORWARD AND REVERSE SWITCH IN NEUTRAL. - DISCONNECT THE BATTERIES AS SHOWN (FIGURE 20-1, PAGE 20-2). 1. Remove the yellow wire and red wire from the large posts of the solenoid. Remove resistor assembly. Place the red (+) probe of the VOM on one of the large posts of the solenoid and the black (-) probe of the meter on the other large post on the solenoid. It should show no continuity. If the VOM shows continuity, replace the solenoid. 2. Using a VOM, check for continuity between both resistor terminals. If reading is not approximately 250 ohms, replace the resistor. Batteries Test Procedure 1 -- Check Battery Pack Voltage B- B+ for > 48v PASS Solenoid Test Procedure 7 - Solenoid Contacts (Power Off): REPLACED NEW - CLICKS - DID NOT REPLACE RESISTOR Forward and Reverse Switch Test Procedure 6 - Forward/Reverse Switch: Testing the Forward and Reverse (F&R) Switch Test Procedure 3 - Forward/Reverse Anti-Arcing Limit Switch: Test Procedure 4 - Accelerator Pedal Limit Switch: Potentiometer Test Procedure 8 - Multi-step Potentiometer: Test Procedure 9 - Continuously Variable Potentiometer: Controller Test Procedure 10 - Solid State Speed Controller: BENCH TEST REPORTED WORKING AS NORMAL Motor To test run a series motor FWIW -- I started pulling together a simple step by step doc from the service manual and other posts I found here. If anyone wants to use feel free. |
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05-08-2015, 04:30 PM | #2 |
Getting Wild
Join Date: Jul 2014
Location: South Carolina
Posts: 111
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Re: 97 Club Car - Won't Move - Solenoid Clicks - Resistor Question
I appear to not have 5v on pin 2 controller input - power source bad any ideas what to check next?
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05-08-2015, 05:15 PM | #3 |
Happy Carting
Join Date: Dec 2007
Location: Southern California
Posts: 73,410
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Re: 97 Club Car - Won't Move - Solenoid Clicks - Resistor Question
In 97 CC made a couple of drive systems.
1. Can you ID your drive system below? 2. What is the battery pack voltage at rest? |
05-08-2015, 08:59 PM | #4 | |
Getting Wild
Join Date: Jul 2014
Location: South Carolina
Posts: 111
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Re: 97 Club Car - Won't Move - Solenoid Clicks - Resistor Question
Quote:
Battery Pack is 48.4v at rest, hasn't been charged in a few weeks. Solenoid REPLACED NEW - CLICKS - Upon Pedal Depressed. RESISTOR SHOWS 239 Ohms Resistance F/R Switch I have no voltage on the F/R switch BLUE or ORANGE cables. (I have a 96DS cart next to it showing 51.4v on the F/R switch with - on B- and + on BLUE / ORANGE cables) |
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05-09-2015, 01:49 PM | #5 |
Getting Wild
Join Date: Jul 2014
Location: South Carolina
Posts: 111
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Re: 97 Club Car - Won't Move - Solenoid Clicks - Resistor Question
I fixed the controller input voltage on pin #2 green (7.8v) when pedal pressed and matches the other cart.
The odd thing is the F/R switch voltage shows 26v in N and 1.7v in F/R. My working cart is 52v in F/R and 10.7v in N Contrasting those two is 1/2 the voltage and sent FROM the motor terminals when in Neutral? What gives - am I staring at a dead / shorted motor? All readings taken from battery #1 negative. |
05-10-2015, 09:01 AM | #6 |
Getting Wild
Join Date: Jul 2014
Location: South Carolina
Posts: 111
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Re: 97 Club Car - Won't Move - Solenoid Clicks - Resistor Question
Get out the butter - motor appears to be toast.
- applied to A1 A2 cross connected to S1 +17v applied to S2 No spark / no load / nothing. |
07-07-2015, 10:07 AM | #7 |
Gone Wild
Join Date: Jul 2015
Location: Central South Carolina
Posts: 939
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Re: 97 Club Car - Won't Move - Solenoid Clicks - Resistor Question
I would think that to indicate a bad motor ... possibly bad brushes or a broken brush spring.
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