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Old 05-11-2017, 09:09 AM   #1
49ford
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Question 82 DS won't run

I just got an 82 DS, not running, thinking it'd be no big deal to get it ginning again shortly. I put new batteries and cables in. Hooked up on/off switch. Nothing. No clicks, no runs.
Rechecked all cables, wires, ohmed f/r microswitch. All good. Bought $5 82 online manual. Went thru tests 1 thru 9. Only thing I found was 4th solenoid had 90 some ohms instead of 58, but,,, they all snap when I put just 24 volts to each of them.
The copper bar on the solenoids looked bad so I pulled it off, cleaned it, posts, nuts and put back on. Nothin. Looks better but no clicks, no runs.
Okay what did I forget?
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Old 05-11-2017, 11:08 AM   #2
crash test dummy
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Default Re: 82 DS won't run

cc test
Quote:
Originally Posted by Sergio View Post
The resistor type cart is a very simple design that does not depend on any electronics to operate, you just need a continuous circuit from pack positive to pack negative for it to work.

Lets try this approach (I am including the FNR picture again for reference):

Disconnect the pack negative cable from the battery, leave any other wires still connected to the pack negative.

Turn the key switch ON

Put the FNR in Forward

Press the pedal and make sure you hear all solenoids engaging.

In the above scenario, the current will flow as follows (using conventional current flow notation for troubleshoot purposes)

Pack Positive -> FNR -> Solenoid on Passenger side -> Copper bus bar -> Solenoid on Drivers side -> Motor A2 -> Motor A1 -> FNR -> Motor S1 -> Motor S2 -> Pack Negative.


Set your meter to DC volts (either auto or 200v scale)

Put meter negative probe on pack negative battery post and keep it there during the entire test procedure.

Press the Pedal all the way down and keep it there during the entire test procedure.

1) Place meter positive probe on disconnected cable coming from S2.
You should read close to pack voltage if everything is working.
Proceed to next step if no voltage reading.
2) Place meter positive probe on motor terminal S2.
If You read close to pack voltage, that cable from pack negative to motor terminal S2 is BAD.
Proceed to next step if no voltage reading.
3) Place meter positive probe on motor terminal S1.
If You read close to pack voltage, the motor Field coil is BAD.
Proceed to next step if no voltage reading.
4) Place meter positive probe on FNR terminal S1.
If You read close to pack voltage, that cable from motor terminal S1 to FNR is BAD.
Proceed to next step if no voltage reading.
5) Place meter positive probe on FNR terminal A1.
If You read close to pack voltage, the FNR is BAD.
Proceed to next step if no voltage reading.
6) Place meter positive probe on motor terminal A1.
If You read close to pack voltage, the cable from FNR to motor terminal A1 is BAD.
Proceed to next step if no voltage reading.
7) Place meter positive probe on motor terminal A2.
If You read close to pack voltage, the motor armature/commutator is BAD.
Proceed to next step if no voltage reading.
8) Place meter positive probe on driver side solenoid where the cable from motor terminal A2 is connected.
If You read close to pack voltage, that cable from motor terminal A2 to solenoid is BAD.
Proceed to next step if no voltage reading.
9) Place meter positive probe on copper buss bar that is connected to ALL solenoids big posts.
If You read close to pack voltage, the drivers side solenoid is BAD.
Proceed to next step if no voltage reading.
10) Place meter positive probe on passenger side solenoid big post where white cable going to FNR is connected.
If You read close to pack voltage, definitely that passenger side solenoid and possible more solenoids are BAD.
Proceed to next step if no voltage reading.
11) Place meter positive probe on FNR terminal #5
If You read close to pack voltage the cable from passenger side solenoid to FNR is BAD
Proceed to next step if no voltage reading.
12) Place meter positive probe on FNR terminal +36v.
If You read close to pack voltage the FNR is BAD.
Proceed to next step if no voltage reading.
13) Place meter positive probe on pack positive battery post.
If You read close to pack voltage that cable from FNR to pack positive is BAD.
Proceed to next step if no voltage reading.
14) Your meter is either bad or not connected to pack negative.
repeat tests

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Old 05-11-2017, 03:10 PM   #3
49ford
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Default Re: 82 DS won't run

did fine till I got to step 7. It read 25 volts. Making me look back at F/R cabling to see if I had 24v cable in wrong spot. It looks right according to my elec diagram with long bent lug going to Pos. one beside going to 24v and top to S1.
Anyhow,,, shouldn't be voltage from neg to A2. I ran it thru checks that my $5 CC manual says and found no grounds or opens. I'd like to check brushes but w/GE you have to pull apart. Might as well rip it out.
I might be done at this point. I thought I had a spare motor, turned out to be an ezgo.
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Old 05-11-2017, 03:46 PM   #4
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Default Re: 82 DS won't run

here's pics of my F/R switch, top to S1, closest to cam 24v, and lug behind 36v
Attached Images
File Type: jpg HPIM3457.JPG (279.0 KB, 0 views)
File Type: jpg HPIM3458.JPG (256.9 KB, 0 views)
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Old 05-15-2017, 05:56 PM   #5
49ford
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Default Re: 82 DS won't run

HELP
I spent a half day cutting rusted spring hanger bolts, removing shocks, and pulling the motor out only to find it runs. It ran so well it almost ran off the cart it was laying on when I jumped it.

I guess I'll take out the throttle micro switches next. It won't CLICK any switches. I can faintly hear micros clicking as throttle goes down but that's all I hear.
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Old 05-15-2017, 06:31 PM   #6
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Default Re: 82 DS won't run

Any guesses?
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Old 05-15-2017, 10:34 PM   #7
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Default Re: 82 DS won't run

no Solenoid click ?
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Old 05-16-2017, 06:30 AM   #8
Sergio
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Default Re: 82 DS won't run

I was not quite clear how You tested the motor, but You cannot run the motor detached from the differential. The armature will rub against the field winding and can get damaged.

The power activation for those old carts is easy to verify.

Raise one rear wheel OFF the ground.

The Negative side common to all solenoids comes from:
Pack Negative -> Charger Receptacle Negative -> Key Switch -> Limit Switch in FNR -> Solenoids.
To test it:
Set meter to DC volts.
Turn Key switch OFF.
Place FNR in Forward.
Place meter negative probe on any of the shared small posts of the solenoids.
Place meter positive probe on pack positive (+36v) battery post.
Meter should read 0.
Turn Key Switch ON, meter should read pack voltage.


The positive side of the Solenoid activation comes from:
Pack Positive -> +36v terminal of FNR -> All micro-switches inside speed box -> Solenoids.
To test:
Set meter to DC volts.
Turn Key switch OFF.
Place FNR in Forward.
Place meter negative probe on pack negative battery post.
Place meter positive probe on any individual solenoid activation small post (not the ones linked together).
Meter should read 0.
Press Pedal, meter should read pack voltage as the micro-switch closes.
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Old 05-16-2017, 06:48 AM   #9
49ford
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Default Re: 82 DS won't run

None of the 5 solenoids click. I can jump each of them and then they will snap shut like they should.
The motor is Hitachi. It has both end plates on it so its looks just like a regular AC motor in that you can test it off the cart.
Goin fishin today so will do the other suggested test later.
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Old 05-16-2017, 07:09 AM   #10
49ford
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Default Re: 82 DS won't run

Problem solved. It was self inflicted. Looking at solenoid activation ladder, I noticed I had no wire from charge recpt. to bat neg. My thought was the white wire is positive in dc, which it is, but on the other side of the plug.
THANK YOU ALL for the help. It seems like a struggle sometimes and sometimes its so easy. Just depends if you follow the diagrams correctly.
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