96 Lifted Club Car DS - Low Voltage on MicroSW

[Fairtax4me]

Power going to your shift lever limit switches comes from solenoid main post on Green wire to the key switch, from there it goes Blue wire to the Throttle switch first, then to the Limit switches on Green/White wire.

Check voltage at the Key switch You should have pack voltage. If not then you need to check the Green wire at the solenoid large post, same as the Red cable from pack Positive. If you have pack voltage at the Green wire at the solenoid, but not at the key switch, replace the wire from the solenoid to key switch.

You should probably replace all of the battery and motor cables especially the ones at the FnR switch, because I see some nasty corrosion and exposed wire in the pics you posted. It may also be a good idea to replace that FnR switch with a heavy duty version since this cart has a higher power motor.

[Mooncarter]

Originally Posted by Fairtax4me

Power going to your shift lever limit switches comes from solenoid main post on Green wire to the key switch, from there it goes Blue wire to the Throttle switch first, then to the Limit switches on Green/White wire.

Check voltage at the Key switch You should have pack voltage. If not then you need to check the Green wire at the solenoid large post, same as the Red cable from pack Positive. If you have pack voltage at the Green wire at the solenoid, but not at the key switch, replace the wire from the solenoid to key switch.

You should probably replace all of the battery and motor cables especially the ones at the FnR switch, because I see some nasty corrosion and exposed wire in the pics you posted. It may also be a good idea to replace that FnR switch with a heavy duty version since this cart has a higher power motor.

Yeah, and he says he has a lighted toggle for a key switch that lights when he presses the go pedal. There's a lot of stuff out of whack here.

[Sergio]

I missed the lighted toggle switch comment....

Reading that comment again on how it is wire it did not mention the Green wire that brings power from the battery pack to the key switch.

If the toggle switch is just wired to the orange/white wire on the battery light then you would be providing a lower voltage to the pedal since the OBC powers the warning light with around 32v and you have it in series with the circuit.

The toggle switch should not light without a negative and it would need to have a 48v light.

[entrican]

Originally Posted by Mooncarter

Yeah, and he says he has a lighted toggle for a key switch that lights when he presses the go pedal. There's a lot of stuff out of whack here.

agreed - i pulled ALL wiring and am now re-wiring the entire cart. First thing I discovered was the FNR switch had been physically altered in such a way that in (F) it raised all 3 micro-switch fingers, in (R) it raised all 3 micro-switch fingers ... who does this kinda crud ... smh

[entrican]

Originally Posted by Sergio

I missed the lighted toggle switch comment....

Reading that comment again on how it is wire it did not mention the Green wire that brings power from the battery pack to the key switch.

If the toggle switch is just wired to the orange/white wire on the battery light then you would be providing a lower voltage to the pedal since the OBC powers the warning light with around 32v and you have it in series with the circuit.

The toggle switch should not light without a negative and it would need to have a 48v light.

Thank you - you've been a big help and I decided to just yank all wiring and re-do it. There's some real cruddy work been done on this cart. Your comment about my FNR switch and the states of the micro-switches lead me to discover the FNR switch had been physically altered in such a way that it activated all 3 fingers in (F) and (R). Who does this sort of crud? smh

Thank you for all the help!

[entrican]

I ended up re-wiring the cart and all is well now. There was some really shotty wiring on this cart, but everything else is in good shape.

Last problem to figure out is shuttering under acceleration. I believe this has something to do with the batteries.

Thanks for all your help!