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Electric Club Car Electric DS, and Precedent golf cars



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Old 08-15-2017, 07:02 AM   #11
LukeL
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Default Re: Need help after converting ‘88 Club Car DS

That’s what I was just doing. One green, six red.

“ pre-charge failure “?


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Old 08-15-2017, 07:22 AM   #12
scottyb
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Default Re: Need help after converting ‘88 Club Car DS

Pre- charge failure in a SR control can indicate a solenoid failure. First thing to check is the pre-charge resistor. Remove cable #1 between the battery pack and the solenoid. Remove the resistor and with the multimeter set to ohms (Ω) check the resistance across the resistor.

Resistance should be close to 250 for 36v and 470 for 48v carts.
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Old 08-15-2017, 07:52 AM   #13
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Default Re: Need help after converting ‘88 Club Car DS

If the pre-charge resistor tests good try a solenoid bypass test.
1. To insure safety & the integrity of this test it is important the cart is on jacks or blocks.
2. Insure the F&R lever is fully moved to the F or R position and the cart will not go with the key on. Do not move the F&R lever until you are finished with this test.
3.Insure the solenoid is clicking when you try to go or if not clicking, that there is battery pack voltage between the 2 small solenoid posts when the gas is depressed.
4. move the 2 big cables to 1 big post and try to go. If the cart runs the solenoid may be defective. If the cart does not run the F&R may be defective assuming you are getting a good throttle signal, no controller fault codes, cables are all tight and the motor is good.
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Old 08-15-2017, 08:00 AM   #14
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Default Re: Need help after converting ‘88 Club Car DS

OK – I did what you said and bypassed the solenoid, and it goes! How do I test the pre charge resistor?


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Old 08-15-2017, 08:03 AM   #15
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Default Re: Need help after converting ‘88 Club Car DS

I do have the pack voltage at the two small terminals if I press the pedal and let the solenoid click


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Old 08-15-2017, 08:06 AM   #16
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Default Re: Need help after converting ‘88 Club Car DS

Watch this short video on my website here > http://www.cartsunlimited.net/troubleshooting-tips.html

Then set your meter to Ωs and place a test lead on each end of the resistor.
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Old 08-15-2017, 08:08 AM   #17
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Default Re: Need help after converting ‘88 Club Car DS

You would not have one of these solenoids by any chance would you?
http://www.buggiesgonewild.com/elect...-solenoid.html
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Old 08-15-2017, 08:13 AM   #18
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Default Re: Need help after converting ‘88 Club Car DS

If the resistor is good;
Assuming we are looking at a 400a brown MZJ solenoid, remove the cap (2 screws).
By hand insure the contact bar can move easily down and springs back up. Sometimes they get hung up. This might be the case since it did work initially.

Put the big cables back where they go on the solenoid and reinstall the resistor. Test the cart again, with the solenoid cap off. See if the contact bar snaps down making solid contact when you press the gas.

Does the cart go?
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Old 08-15-2017, 08:15 AM   #19
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Default Re: Need help after converting ‘88 Club Car DS

I have the black 200a solenoid. I will go check the resistor now.


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Old 08-15-2017, 08:20 AM   #20
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Default Re: Need help after converting ‘88 Club Car DS

He does not have one of the bad solenoids because I stopped selling them after I wrote that document. Others still sell them because they are cheap.
He has identified the solenoid as the SW180 solenoid with magnetic breakout.
This solenoid is polarity sensitive.
1. Be sure your main battery cable is connected to the big post marked (+)
2. And the red connector on the diode I sent is on the small post marked (+)
3. And the go pedal blue wire is on the positive post (+) assuming rotary F&R installation

This solenoid rarely goes bad but, I do not suggest taking it apart. If it is the source of the problem simply return it to me for repair or replacement.
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File Type: jpg SW 180 b.JPG (31.3 KB, 0 views)
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