1999 DS Cart won't move

Hitandrun · 04-11-2014, 08:38 AM

My name is Greg, and I am in Northern California. This is my first post. I recently bought a 1999 Club Car DS 48V series cart. F-R lever rather than rocker switch and no tow mode switch. The cart has been remanufactured from top to bottom, with almost every component being new. Transaxle, motor, all suspension and steering, batteries, wiring, etc. I have used it for about a dozen rounds of golf with no problems. Yesterday I was starting from a stop when the cart gave a small lurch, and wouldn't move in either direction. I hear a solenoid pick when I depress the pedal , and it makes a faint effort to move, but can't. I put it in neutral and towed it a quarter mile home, and put it up on blocks. With no load, it will turn the wheels slowly with a shudder of effort in either direction. I can't see any mechanical linkage problem. The battery pack shows 50.9 volts, with each battery testing at 8.48 or 8.49 volts. I suppose my next move is to open up the slice of pie shaped controller between the batteries that is connected to the pedal linkage. Just looking for some direction from some of you guys who obviously know these carts far better than I do. Thanks in advance for any advice.

Stevegrmich · 04-11-2014, 08:58 AM

. . . if you can, load test each battery and also check the SG of each cell in each battery . . . that is where I would start . . . also check all connections that they are clean/tight . . . a battery can appear to be "good", ie, full charge, but have a bad cell that brings down the whole pack under load . .

. . . and Welcome to BGW!

smackdaddy66 · 04-11-2014, 09:03 AM

I had a cart that acted similarly. Ended up being a loose connection on one if the battery terminals.

Smackdaddy66

scottyb · 04-11-2014, 10:18 AM

I agree - these guys are steering you in the right direction. Check the battery pack first.

Hitandrun · 04-11-2014, 03:19 PM

OK. I will check all cable connections at the batteries and also motor, etc. I will have some time this afternoon to chase it. I hope it is something that simple. I will post results tonight or tomorrow. Thanks, guys

Hitandrun · 04-12-2014, 07:03 AM

All cable connections at the battery, motor, and everywhere else are clean and tight. My only way to load test the batteries was to monitor voltage at each one when I throttle up the cart, and all were very good. I do get a strong battery acid smell when I throttle up the cart. The wheel turn, but slowly and noisily. Also, what I originally thought was the solenoid picking when I press the pedal is actually a micro-switch. I jumpered the solenoid with the same results. Are there tests I can do to isolate a component?

Hitandrun · 04-15-2014, 02:03 PM

Well, this has been interesting. I have been chasing this problem for a couple of days. I got a hydrometer and checked all the batteries, no problems. I downloaded the manual and read the troubleshooting section. With the cart up on blocks, I still didn't have room to access several points, so I removed the canopy and the rear body. I did all the tests for won't move-solenoid clicks. Solenoid, F-R switch, controller, potentiometer, motor, etc. NTF. I did all tests for cart runs slow, and when I got to On Board Computer Lockout, I ran the tests and then tried the cart, and it worked fine. I have not put everything back together yet, but with no load, it is fine.

Hitandrun · 04-16-2014, 02:32 PM

Well, my cart is back to working like new. It now seems that all this monkey motion I went through could have been avoided by simply taking battery power away from the On Board Computer to reset it. That leaves me with the question: Why isn't that the first item on any troubleshooting checklist? I am carrying a 1/4" ratchet and 1/2" socket on the cart, so if it happens again, I won't be stranded. FOR ANYBODY WHO EXPERIENCE SIMILAR SYMPTOMS, YOUR FIRST MOVE SHOULD BE TO DISCONNECT AND RECONNECT THE BATTERY PACK. I hope my experience will save somebody else the headaches I went through.

Stevegrmich · 04-16-2014, 02:41 PM

Quote:

Originally Posted by Hitandrun

Well, my cart is back to working like new. It now seems that all this monkey motion I went through could have been avoided by simply taking battery power away from the On Board Computer to reset it. That leaves me with the question: Why isn't that the first item on any troubleshooting checklist? I am carrying a 1/4" ratchet and 1/2" socket on the cart, so if it happens again, I won't be stranded. FOR ANYBODY WHO EXPERIENCE SIMILAR SYMPTOMS, YOUR FIRST MOVE SHOULD BE TO DISCONNECT AND RECONNECT THE BATTERY PACK. I hope my experience will save somebody else the headaches I went through.

. . . what you describe as your "fix" actually points to a different problem . . .

Hitandrun · 04-18-2014, 08:07 AM

Okay. What would the problem be?

04-11-2014, 08:38 AM	#1
Hitandrun Not Yet Wild Join Date: Feb 2014 Location: Woodland, CA Posts: 7	1999 DS Cart won't move My name is Greg, and I am in Northern California. This is my first post. I recently bought a 1999 Club Car DS 48V series cart. F-R lever rather than rocker switch and no tow mode switch. The cart has been remanufactured from top to bottom, with almost every component being new. Transaxle, motor, all suspension and steering, batteries, wiring, etc. I have used it for about a dozen rounds of golf with no problems. Yesterday I was starting from a stop when the cart gave a small lurch, and wouldn't move in either direction. I hear a solenoid pick when I depress the pedal , and it makes a faint effort to move, but can't. I put it in neutral and towed it a quarter mile home, and put it up on blocks. With no load, it will turn the wheels slowly with a shudder of effort in either direction. I can't see any mechanical linkage problem. The battery pack shows 50.9 volts, with each battery testing at 8.48 or 8.49 volts. I suppose my next move is to open up the slice of pie shaped controller between the batteries that is connected to the pedal linkage. Just looking for some direction from some of you guys who obviously know these carts far better than I do. Thanks in advance for any advice.

04-11-2014, 08:58 AM	#2
Stevegrmich Medicare Recipient Join Date: Jun 2011 Location: West Michigan Posts: 3,541	Re: 1999 DS Cart won't move . . . if you can, load test each battery and also check the SG of each cell in each battery . . . that is where I would start . . . also check all connections that they are clean/tight . . . a battery can appear to be "good", ie, full charge, but have a bad cell that brings down the whole pack under load . . . . . and Welcome to BGW!

04-11-2014, 10:18 AM	#4
scottyb Happy Carting Join Date: Dec 2007 Location: Southern California Posts: 73,408	Re: 1999 DS Cart won't move I agree - these guys are steering you in the right direction. Check the battery pack first.

04-11-2014, 03:19 PM	#5
Hitandrun Not Yet Wild Join Date: Feb 2014 Location: Woodland, CA Posts: 7	Re: 1999 DS Cart won't move OK. I will check all cable connections at the batteries and also motor, etc. I will have some time this afternoon to chase it. I hope it is something that simple. I will post results tonight or tomorrow. Thanks, guys

04-12-2014, 07:03 AM	#6
Hitandrun Not Yet Wild Join Date: Feb 2014 Location: Woodland, CA Posts: 7	Re: 1999 DS Cart won't move All cable connections at the battery, motor, and everywhere else are clean and tight. My only way to load test the batteries was to monitor voltage at each one when I throttle up the cart, and all were very good. I do get a strong battery acid smell when I throttle up the cart. The wheel turn, but slowly and noisily. Also, what I originally thought was the solenoid picking when I press the pedal is actually a micro-switch. I jumpered the solenoid with the same results. Are there tests I can do to isolate a component?

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04-11-2014, 09:03 AM	#3
smackdaddy66 Getting Wild Join Date: Jun 2013 Location: Sugar Land, TX Posts: 126	I had a cart that acted similarly. Ended up being a loose connection on one if the battery terminals. Smackdaddy66

04-15-2014, 02:03 PM	#7
Hitandrun Not Yet Wild Join Date: Feb 2014 Location: Woodland, CA Posts: 7	Re: 1999 DS Cart won't move Well, this has been interesting. I have been chasing this problem for a couple of days. I got a hydrometer and checked all the batteries, no problems. I downloaded the manual and read the troubleshooting section. With the cart up on blocks, I still didn't have room to access several points, so I removed the canopy and the rear body. I did all the tests for won't move-solenoid clicks. Solenoid, F-R switch, controller, potentiometer, motor, etc. NTF. I did all tests for cart runs slow, and when I got to On Board Computer Lockout, I ran the tests and then tried the cart, and it worked fine. I have not put everything back together yet, but with no load, it is fine.

04-16-2014, 02:32 PM	#8
Hitandrun Not Yet Wild Join Date: Feb 2014 Location: Woodland, CA Posts: 7	Re: 1999 DS Cart won't move Well, my cart is back to working like new. It now seems that all this monkey motion I went through could have been avoided by simply taking battery power away from the On Board Computer to reset it. That leaves me with the question: Why isn't that the first item on any troubleshooting checklist? I am carrying a 1/4" ratchet and 1/2" socket on the cart, so if it happens again, I won't be stranded. FOR ANYBODY WHO EXPERIENCE SIMILAR SYMPTOMS, YOUR FIRST MOVE SHOULD BE TO DISCONNECT AND RECONNECT THE BATTERY PACK. I hope my experience will save somebody else the headaches I went through.

04-18-2014, 08:07 AM	#10
Hitandrun Not Yet Wild Join Date: Feb 2014 Location: Woodland, CA Posts: 7	Re: 1999 DS Cart won't move Okay. What would the problem be?

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