Need help after converting ‘88 Club Car DS

[LukeL]

Hi everyone- I just finished installing scottyb’s conversion kit in my formerly-resistor Club Car. I got everything wired, triple checked my wiring, and gave it a try.

It worked fine, and I tried both directions with the back jacked up. I then set it down, got on, and put it in reverse to back out of the carport, and it went fine. When I got out, I switched it to forward and it wouldn’t go. Now it won’t go in either direction.

The batteries are fine, all connections seem good, and the solenoid clicks when I push the pedal. The status light on the controller flashes green if I push the pedal, and if I “floor it” it flashes orange.

Does anybody have any idea why it’s doing this?

Thank you in advance,
Luke


Club Car DS Driver’s Club #59

[NoleFan4Ever]

Put your meter on the outgoing side of the solenoid. It may click, but you need to see if it has pack voltage coming through it.

[LukeL]

I have the full pack voltage (around 3 on BOTH big posts on the solenoid while not holding the pedal.

When I press the pedal, the solenoid clicks and the controller side of the solenoid drops about ten volts.

What’s going on?


Club Car DS Driver’s Club #59

[NoleFan4Ever]

When you converted did you maintain 36v or upgrade to 48v?

And you should not be getting pack voltage to the motor/controller side of the solenoid unless it is closed in. Is the solenoid stuck in the closed position? Take off the to activation wires and check it then. Also if it seems bad, take it off and test it. You should have continuity through the 2 small posts, no continuity through the 2 large posts. If that checks out, activate the solenoid and then verify you do now have continuity at the 2 large posts.

[LukeL]

Ok. I will do that tomorrow morning. Thank you.

I kept 36 v for the time being, because I got my batteries in June. When I replace them, I will go up. I will probably find another cart needing a 36 v pack soon.


Club Car DS Driver’s Club #59

[scottyb]

Originally Posted by NoleFan4Ever

When you converted did you maintain 36v or upgrade to 48v?

And you should not be getting pack voltage to the motor/controller side of the solenoid unless it is closed in. Is the solenoid stuck in the closed position? Take off the to activation wires and check it then. Also if it seems bad, take it off and test it. You should have continuity through the 2 small posts, no continuity through the 2 large posts. If that checks out, activate the solenoid and then verify you do now have continuity at the 2 large posts.

This solenoid has a pre-charge resistor on it. It will always show pack voltage on both sides of the solenoid while the pre-charge resistor is installed. Please be careful

[LukeL]

Ok. So what’s the problem then? The solenoid is clicking.


Club Car DS Driver’s Club #59

[LukeL]

It’s still doing the same thing. I disconnected the battery pack and reconnected it, and checked all connections, but it still just clicks.


Club Car DS Driver’s Club #59

[LukeL]

Also there is no solid green light on the controller. Only flashes when I press the throttle.


Club Car DS Driver’s Club #59

[scottyb]

What is the status code that is flashing? And what color is it. See the list of 'blink codes' on page 24 in the operator's manual. The controller should indicate the direction of the trouble source or at least give a starting point.

We know it was all connected correctly if the cart wheels turned in both directions. So I would suspect a loose connection.