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Club Car Troubleshooting
CHECKING CONTROLLER INPUT and OUTPUT
Connect (-) probe to B- terminal. Connect (+) probe to B+ terminal.
The reading should indicate approx. 0 volts with the resistor REMOVED and the pedal not pressed in the last 15-30 minutes.
Slowly depress accelerator pedal until the solenoid engages. Check the meter.
The reading should show the battery pack voltage. Now depress the pedal and watch the reading go down near 0 volts.
If the voltage starts at full pack and goes down near zero when the pedal is depressed and the motor is not responding then the problem lies in the high amperage side of the drive circuit. Check the cable connections, the forward and reverse switch, and the motor.
MOTOR UNWANTED CONTINUITY TEST
The following tests can assist in troubleshooting.
Disconnect all wires to the motor and label them
Make sure none of the terminals are grounded to the motor or cart (F1 terminal to motor frame) You should have continuity present between F1 and F2 and A1 and A2 but NOT BETWEEN ANY A and ANY F Terminal.
If any of these test fail, the motor will not operate correctly.
Micro Switch Testing
The micro switches are simple 2 wire on/off switches. They open and close mechanically.
You can test function with a voltmeter if you first verify 36v in on the supply side of the switch, then mechanically trigger the switch, and test for 36v on the output side.
With the multi-meter set to continuity or ohms you can disconnect both sides of the switch and connect it to the meter. The meter will show the connection making and breaking. If not check meter settings and test a different switch. Once you are certain your test method is correct retest the switch in question.
FORWARD & REVERSE SWITCH aka F&R
Series rotary mechanical type
The forward and reverse switch is a simple Rotary device. Four contacts are stationary in the switch housing. And four contacts are on a rotating center cam. This configuration allows for three configurations; forward, neutral, and reverse. Contact is maintained by spring tension and friction.
You can test for continuity between parallel pairs of stationary lugs in forward and reverse position. However, the Ω test will not guarantee that the contact is good enough to withstand high amperage. It is possible to have a positive continuity test that will not hold up to actual use. A visual inspection is best. If all of the four studs are not identical in color, one or more may have gotten hot. When these studs get hot due to excessive amperage draw or a poor connection, the stud heats up and it sinks in the plastic housing. This compromises the contact with the lug in the rotating cam. If a stud has sunk or changed angle so it appears to lean then the complete switch must be replaced.
Rocker switch test
The rocker switch F&R on Sepex carts has power in on the center pin and power out on 1 of the 2 outer pins when each direction is selected. A simple voltage check will verify operation.