Cart will not move----need some help

[jackfunkey]

Cart is a 1995 club cart DS. It is a 48v cart with Trojan 875 batteries. Last year I burned up a wire on the cart from too much load on it. Anyways, replaced wire from negative of battery pack to controller and now the cart will not move. I put it in forward or reverse gear and step on the pedal and you hear a slight click and nothing. Checked and load tested each battery and they are all at 8volts. I was reading and maybe my POTENTIOMETER is bad? How do I test this?

 

[shadowman]

i take it you replaced the cable that ran thur the hole in the OBC? if so did you put the new one thur that hole if not thats your problem..........................................

 

[jackfunkey]

Are you serious about passing the cable through the hole?? I did not do that, I put a slightly thicker cable in there so It would not fit through the hole in the OBC and I thought with the thicker cable it would be better for the car. So if I pass that through the hole the cart should work?

Thanks for the help shadowman!!!

 

[HotRodCarts]

The cable has to go through the hole on the OBC. What size cable did you use? If it's 4 gauge it will fit but you may have to cut the lug off and crimp/solder it on after the cable is in the OBC.

 

[shadowman]

Yes put it thru as mentioned you will have to take the lug off one end and put it back on after your thru.

 

[jackfunkey]

Ok, sorry guys, I have not updated this. I used a 4 gauge wire that had a thick jacket around the wire. I took a drill bit and opened up the whole (barely) just to fit the wire in the. Did not break the plastic or anything. Wire is now through the hole on the computer and hooked everything up and NOTHING!! I just put the car in FWD and press the pedal and "CLICK". I measured the battery packs and they are reading around 48.6 volts. I know that this cart will need batteries but at 48.6 volts, I would think the cart should move.

What can I try next

?

 

[shadowman]

i think by drilling that hole a little bigger you ruined OBC the plastic is part of a sensor and you just might have ruined it...........thats my thoughts so it might be OBC time now.......................................

 

[golfdog]

If the Clicking is coming from the solenoid then its unlikely that the OBC is at fault. There is a 10 gauge yellow wire running from the small post on the solenoid to the OBC. This isolates the solenoid when the charger is connected to prevent the car from being driven. Try disconnecting this wire at the solenoid and connecting a 10 gauge wire from the same solenoid post to the negative of #6 battery. If the car then goes the OBC is at fault. This fault is not fatal as you will just have to leave the yellow wire disconnected. The car should charge as normal but will also go if you accidentally drive off with the charger plugged in. Even if the solenoid clicks it may be carboned up inside so you can try bridging the large posts with 4 gauge and see if it goes

 

[shadowman]

if you bypass the OBC your charger will not shut off...........and just for giggles the yellow wire is 16 gage not 10 gage....................i have worked on plenty of carts where the solenoid clicks and problem turned out to be OBC so thats a 1st for me......................let us know what you find...........................................