Lost power DS

[yamahaguy97]

Hey

I work on the club car DS fairly often but I encountered a much older coil style with the solenoids. Long story short I had it running but apparently left it stationary for a few days with the key on and in F. Come to find out now it won't move, and the first solenoid is extremely hot. I don't know everything about golf carts but I was under the impression that leaving it in f or r drains very little power, certainly not enough to kill the cart after a few days. But I seem to be wrong

Is my issue that the very hot solenoid is burned up now because I left it in f and it received full voltage over 3 days? I can tell you the pack voltage reads around 36.5. With no one around to depress the gas pedal I don't see how it drained battery power and killed the cart by leaving the key on and in gear.

Someone please explain what happened to it more eloquintly lol

Thanks again

club car ds

key on >
F/R SWITCH IN F OR R >
GO PEDAL PRESSED >
MAIN MICRO SWITCH >
MAIN SOLENOID >
PRESSING GO PEDAL MORE >
1ST SPEED MICRO SWITCH >
1ST SPEED SOLENOID & ALL COILS >
PRESSING GO PEDAL MORE >
2ND SPEED MICRO SWITCH >
2ND SPEED SOLENOID & 2 COILS >
PRESSING GO PEDAL MORE >
3RD SPEED MICRO SWITCH >
3RD SPEED SOLENOID & 1 COIL >
PRESSING GO PEDAL FULLY >
FULL SPEED MICRO SWITCH >
FULL SPEED SOLENOID & NO COILS

with out the go pedal pushed it does not pull power
BUT if main solenoid is welded shut it will pull power
pull main negative cable and replace the solenoid

note : i like to replace all 5 solenoid

[yamahaguy97]

Originally Posted by crash test dummy

club car ds



with out the go pedal pushed it does not pull power
BUT if main solenoid is welded shut it will pull power
pull main negative cable and replace the solenoid

note : i like to replace all 5 solenoid

Thanks crash

Its a fairly new solenoid but oh well. It must be welded because it was burning hot

[Sergio]

Originally Posted by yamahaguy97

Thanks crash

Its a fairly new solenoid but oh well. It must be welded because it was burning hot

A welded solenoid would not get hot in that cart under your conditions since there is no current path.

Most likely the first micro-switch in the speed box is either bad or wired incorrectly which is causing the solenoid to engage as soon as the key switch is ON and the limit switch in the FNR closes.

You can verify that by turning the key switch ON and OFF and listening for the solenoid to click.

[yamahaguy97]

Originally Posted by Sergio

A welded solenoid would not get hot in that cart under your conditions since there is no current path.

Most likely the first micro-switch in the speed box is either bad or wired incorrectly which is causing the solenoid to engage as soon as the key switch is ON and the limit switch in the FNR closes.

You can verify that by turning the key switch ON and OFF and listening for the solenoid to click.

The key alone is not engaging the solenoid. Once I turn the key on and put it in F then I hear the solenoid engage. The cart was running normally last week with normal performance. I come back to work and suddenly no go. All I know is if the first solenoid is not working. Then the car is not going to run.

[yamahaguy97]

I'm only hearing 4 clicks, not 5 clicks, so that solenoid has to be replaced either way even though that solenoid is only 2 weeks old.

[Sergio]

You need both the key switch and the FNR limit switch closed for power to be available for the Solenoid coils.

The solenoid however should not engage until the corresponding micro-switch closes inside the speed box.

Are you sure the first Solenoid micro-switch is wired correctly and not to the N.C. tab which would cause your exact symptoms?

[yamahaguy97]

Sergio

Yes, I'm sure everything is wired properly. I just got to work and examined the primary solenoid closer. It turns out on one of the small terminals, the wire is very loose and the solenoid is cracked in that area. I hate to admit it, but I probably didn't tighten it quite good enough, and it was arcing around and it caused it to crack. Thanks for your help, though, and that goes for everybody else that chimed in

[yamahaguy97]

Remember people tightening wires down is very important!!!