2003 club car DS - been sitting - won't go ?

1arunem · 07-20-2016, 11:42 AM

Working on a buddies 2003 Club Car DS 48volt (no tow switch).

Cart has been sitting for a couple of years. First thing we did was put in a fresh set of batteries.

Key on, cart will only make a clicking noise when pedal is depressed.

First things to check? Thanks in advance!

Frizbgolf · 07-20-2016, 01:29 PM

Did you charge the batteries after installing them, are you sure the batts are wired properly. What is the serial # of the cart (look for a sticker under the glove box area near where steering column goes thru). Just a few things to check and answer and to help the gurus here get you on the right track.

1arunem · 07-20-2016, 08:31 PM

Batteries are brand new, they were charged, showed 50.2 volts. Doubled checked battery wiring.

Serial number is AA0336-320530

BTW the wire going to the F/R switch is getting kind of hot.

1arunem · 07-21-2016, 08:39 AM

A little followup.. Charge will not charge batteries.. Checked fuse behind charger receptacle and it appears good.

Can someone verify the procedure to check for a bad OBC?

Thanks!

TahoeDawgZ71 · 07-21-2016, 08:39 AM

Check your connections at the F&R switch really good. Spray some contact cleaner on the back of the switch and work it back and forth a few times to clean off the copper. Inspect the switch really good to make sure it's not melted around the connections. You may want to completely remove the switch to look at the front of it. It tends to melt there often.

1arunem · 07-21-2016, 08:11 PM

Checked and cleaned FR switch. Still nothing. Reset OBC per instructions, light comes on but no movement. Still just a clicking solenoid.

Bypassed OBC (jumper from fused charger receptacle wire to #6 battery neg) and charger started charging..

Bad OBC????

Thanks..

Epb · 07-21-2016, 08:54 PM

Is that fuse bad or missing in the gray sense wire?

1arunem · 07-22-2016, 08:22 AM

Fuse appears OK..

TahoeDawgZ71 · 07-22-2016, 08:47 AM

If your solenoid is clicking, the OBC is not the problem that is keeping the cart from running. You may have a bad OBC if the cart won't charge, but if the solenoid is clicking you can rule it out as the culprit for the car not moving. Tap the solenoid with a hammer and see if you can make it go. Often, when a vehicle sits up for a long time the solenoid needs to be replaced. Tapping it with a hammer after it has engaged sometimes will make just enough of a connection to make the cart run.

1arunem · 07-27-2016, 04:06 PM

Little more info. Cart does NOT have tow switch. However, cart will NOT roll on flat ground. Wheels will turn by hand (in opposite directions) when jacked off the ground.

Tried tapping solenoid with a hammer and no change..

Suggestions?

07-20-2016, 11:42 AM	#1
1arunem Gone Wild Join Date: Nov 2015 Posts: 460	2003 club car DS - been sitting - won't go ? Working on a buddies 2003 Club Car DS 48volt (no tow switch). Cart has been sitting for a couple of years. First thing we did was put in a fresh set of batteries. Key on, cart will only make a clicking noise when pedal is depressed. First things to check? Thanks in advance!
1arunem Gone Wild Join Date: Nov 2015 Posts: 460

07-20-2016, 01:29 PM	#2
Frizbgolf Gone Wild Join Date: Nov 2009 Location: Picayune, Mississippi Posts: 881	Re: 2003 club car DS - been sitting - won't go ? Did you charge the batteries after installing them, are you sure the batts are wired properly. What is the serial # of the cart (look for a sticker under the glove box area near where steering column goes thru). Just a few things to check and answer and to help the gurus here get you on the right track.

07-20-2016, 08:31 PM	#3
1arunem Gone Wild Join Date: Nov 2015 Posts: 460	Re: 2003 club car DS - been sitting - won't go ? Batteries are brand new, they were charged, showed 50.2 volts. Doubled checked battery wiring. Serial number is AA0336-320530 BTW the wire going to the F/R switch is getting kind of hot.
1arunem Gone Wild Join Date: Nov 2015 Posts: 460

07-21-2016, 08:39 AM	#4
1arunem Gone Wild Join Date: Nov 2015 Posts: 460	Re: 2003 club car DS - been sitting - won't go ? A little followup.. Charge will not charge batteries.. Checked fuse behind charger receptacle and it appears good. Can someone verify the procedure to check for a bad OBC? Thanks!
1arunem Gone Wild Join Date: Nov 2015 Posts: 460

07-21-2016, 08:39 AM	#5
TahoeDawgZ71 revolutiongolfcars.com Join Date: Mar 2010 Location: Golf Car Capital of The World... Augusta, Georgia Posts: 10,224	Re: 2003 club car DS - been sitting - won't go ? Check your connections at the F&R switch really good. Spray some contact cleaner on the back of the switch and work it back and forth a few times to clean off the copper. Inspect the switch really good to make sure it's not melted around the connections. You may want to completely remove the switch to look at the front of it. It tends to melt there often.

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07-21-2016, 08:11 PM	#6
1arunem Gone Wild Join Date: Nov 2015 Posts: 460	Re: 2003 club car DS - been sitting - won't go ? Checked and cleaned FR switch. Still nothing. Reset OBC per instructions, light comes on but no movement. Still just a clicking solenoid. Bypassed OBC (jumper from fused charger receptacle wire to #6 battery neg) and charger started charging.. Bad OBC???? Thanks..
1arunem Gone Wild Join Date: Nov 2015 Posts: 460

07-21-2016, 08:54 PM	#7
Epb Gone Wild Join Date: Mar 2012 Location: Katy, Tx Posts: 1,027	Re: 2003 club car DS - been sitting - won't go ? Is that fuse bad or missing in the gray sense wire?

07-22-2016, 08:22 AM	#8
1arunem Gone Wild Join Date: Nov 2015 Posts: 460	Re: 2003 club car DS - been sitting - won't go ? Fuse appears OK..
1arunem Gone Wild Join Date: Nov 2015 Posts: 460

07-22-2016, 08:47 AM	#9
TahoeDawgZ71 revolutiongolfcars.com Join Date: Mar 2010 Location: Golf Car Capital of The World... Augusta, Georgia Posts: 10,224	Re: 2003 club car DS - been sitting - won't go ? If your solenoid is clicking, the OBC is not the problem that is keeping the cart from running. You may have a bad OBC if the cart won't charge, but if the solenoid is clicking you can rule it out as the culprit for the car not moving. Tap the solenoid with a hammer and see if you can make it go. Often, when a vehicle sits up for a long time the solenoid needs to be replaced. Tapping it with a hammer after it has engaged sometimes will make just enough of a connection to make the cart run.

07-27-2016, 04:06 PM	#10
1arunem Gone Wild Join Date: Nov 2015 Posts: 460	Re: 2003 club car DS - been sitting - won't go ? Little more info. Cart does NOT have tow switch. However, cart will NOT roll on flat ground. Wheels will turn by hand (in opposite directions) when jacked off the ground. Tried tapping solenoid with a hammer and no change.. Suggestions?
1arunem Gone Wild Join Date: Nov 2015 Posts: 460

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