86 Club Car troubleshooting - where to start and what to test

[bcontento]

Originally Posted by Sergio

That is a problem, nothing should click when you turn the Key ON and put the FNR in forward or reverse.

The main solenoid should not click until activated by the first micro-switch inside the speed box.

I misspoke. I installed the new solenoid and the bank of speed control microswitches. No solenoid clicking until the the throttle is depressed and I do hear all 5 engage in sequence now.

I'm charging the cart up again now and will give it a roll this evening to see how things go. To me, it sounds like I'm going to need batteries. I don't have a 20vDC setting on my volt meter to run a load test like that, but I can see about acquiring one. Should the battery voltage remain constant at rest vs. under full throttle to indicate good load capability?

I'm sure this is discussed elsewhere, and I'll search for it, but what are my options for inexpensive batteries? I certainly don't want to drop $1k on Trojans.

[bcontento]

Update:

The pack took a full charge and showed around 53 volts. Took it for a test drive and the cart flew for a little while but then quickly began to deteriorate. The LED voltmeter I installed in line steadily dropped into the mid to low 30s and the percentage display dropped quickly to virtually zero under Full Throttle.

So is it batteries? I did find a place near me where I can get a set of 6 Trojan 875 for $730

[ecaldwell78]

I know it is a big chunk of change, but batteries should NOT be dropping that far under load. It sounds as if the plates were left exposed for too long. I would be replacing the pack, but that's just my two pennies.

[bcontento]

Well, new set of Trojans installed and it's like a new cart. The thing FLIES now even with all 4 of us in it. The battery meter shows like 53v fully charged and hovers between 47v and 49v during travel even at WOT. No loss of power or torque after a good 30 minute run (mostly WOT) with headlights, taillights, radio, and LEDs on.

Still one bug to work out. It seems to have a flat spot in the acceleration. It accelerates smoothly to a point then all of a sudden JUMPS into high gear. Would that likely be an issue with one of the microswitches (all new) or one of the solenoids (also all new) or possible the resistor coils? I would assume the first two solenoids are OK since it goes at all (#1) and goes slowly fine (#2). I also would think the last one (#5) is fine because it goes fast and it goes in reverse. So possibly something with #3 or #4 solenoid?

thanks again all!

[Sergio]

If the slowest speed works, it means ALL resistor coils are good since power needs to pass through all of them in the slowest speed.

Make sure the Solenoids are all closing.

One trick that makes it easier for testing is to:

Put FNR in Neutral so the motor cannot run.
Turn Key switch ON.
Place your finger on the FNR micro-switch and activate it so the solenoid coils get power.

You can now press the pedal and test the solenoids as they will activate normally but the cart will not run.