1986 club car

[jaburke]

my club car takes off in high speed as soon as you turn the dial to forward or reverse.

[golfcartg]

It sounds like you may be experiencing issues with the microswitches inside the speed box. If the cart only operates when the key is ON but the pedal isn't pressed, this could indicate a problem with the micro-switches. Additionally, you should hear the solenoids click when the key is turned ON, so be sure to listen for that as well.

If the cart runs with the key OFF, it's possible that two solenoids are stuck. Take a close look at the solenoids to make sure that none of the wires coming from the speed box are touching the resistor coils or buss bar.

When the issue only occurs in Forward, it's likely that one or more of the positive solenoid small posts is touching the resistor coil assemblies. These solenoids only have pack voltage on Forward, so this could be causing the problem. Be sure to inspect all connections and components carefully to pinpoint the issue, and let me know if you need further assistance!

[golfcartg]

Some more detail on club cars with the 5 solenoid system. When you press down on the pedal, a sequence of events unfolds within the control box, also known as the speed box or throttle box. Let's break it down: Microswitch 1 kicks things off by signaling the master solenoid closest to the driver's side. This master solenoid serves as the gateway between the motor and the bussbar, but since there's no voltage at the bussbar yet, the cart stays put. Moving on to microswitch 2, it activates the next solenoid in line, nudging the cart into motion at its lowest speed. This is because power has to weave through all the resistor coils before reaching the bussbar, resulting in maximum resistance. As we hit microswitch 3, power is granted passage through one less resistor coil, reducing resistance and allowing more current to flow to the motor."

Microswitch 4 ups the ante by letting current skip through two less resistor coils, delivering more power to the motor and ramping up the speed. Finally, microswitch 5 unleashes the full potential as it establishes a direct current path from the Forward/Reverse (FNR) switch to the buss bar and onwards to the motor, bypassing any resistor coils altogether. This direct connection unleashes maximum power and speed.

These solenoids are specifically designed for continuous 36v duty in golf carts, so there's no room for automotive substitutes here, they simply won't hold up in the long run. Each solenoid boasts two activation posts, requiring both positive and negative inputs to trigger the closing of the contacts between the larger posts. The negative side of the solenoid's activation feed is linked together, with all solenoids sharing a common source from the Forward/Reverse microswitch via the key switch.