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Unread 12-06-2015, 05:59 PM   #11
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Default Re: '02 DS fully charged, shudders, slow, & hot cables

As you press the pedal the solenoids should click one at a time. I think the first one just supplies power to the others. As each solenoid ( switch) closes you should gain more speed and power. Make sure they work in sequence and are closing as they should. I think there are micro switches in the throttle that operate the solenoids.

I have never seen one of these carts in person, I'm going on what I have read on this forum.
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Unread 12-07-2015, 11:46 AM   #12
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Default Re: '02 DS fully charged, shudders, slow, & hot cables

Have you lifted the rear with a jack and verified that the brakes weren't dragging? If you got some junk in the brake linkage, it my be dragging a bit

Chase voltage from cable end to cable end throughout your system and verify you are getting correct voltage. Also verify a proper signal from your controller to your main solenoid

A hot motor (to me) has always been due to excessive load or strain. Im not a pro by any means, this is just based off my experiences
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Unread 12-07-2015, 02:59 PM   #13
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Default Re: '02 DS fully charged, shudders, slow, & hot cables

sounds to me like the motor is bad. just fixed one recently that exhibited the same behavior; hot wires on cables to motor, jerking, slow to move
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Unread 12-08-2015, 05:31 PM   #14
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Default Re: '02 DS fully charged, shudders, slow, & hot cables

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Originally Posted by smackdaddy66 View Post
sounds to me like the motor is bad. just fixed one recently that exhibited the same behavior; hot wires on cables to motor, jerking, slow to move
I think you're right. I called a local golf cart repair shop and talked to a tech there. He said towing the cart without flipping the tow/run switch almost certainly killed the motor. He said the burned cutch smell is a near certain indication of a burnt motor. He said the controller may also have been damaged, though perhaps not. Test the motor first by checking resistance/continuity across A1 & A2 and across S1 & S2 and checking for a short to the case. Start with a motor replacement first (if needed) and then only the controller if output voltage from the controller is still low.

I'll be pulling the motor soon to give it an inspection...
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Unread 12-08-2015, 06:50 PM   #15
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Default Re: '02 DS fully charged, shudders, slow, & hot cables

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Originally Posted by mrdane View Post
Ok. Here's an update on what I've discovered so far:

Cable connections were all secure. Also, I should mention step-daughter had her boyfriend tow the cart a few days before these issues started.

Battery pack total voltage: 50.3 volts

All but one battery showed 8.4 volts, the other showed 8.3 volts. I used an electrolyte tester that used 4 floating balls to test each cell. All cells floated all four balls except for one cell on the low voltage battery. 3 floated and one was halfway sinking. Batteries are from 2012.

Measured resistance from the controller for the accelerator (green and yellow wires to the controller.) Initially reading was OL (open circuit). Even after I heard the solenoid click I still was seeing OL. Eventually, I was getting a highest reading of about 4300 and a low reading with the pedal all the way down of about 1055.

Voltage input on the controller was the same as the battery pack voltage.

Voltage output on the controller never got above 11 volts.

To those who know, any recommendations?
Take the Multi-Step Potentiometer, pie shaped looking box connected to the throttle linkage apart.

The first resistor is bad, #26 in the picture, it should be around 910Ω 1/4 watt.

Throttle linkage either needs to be adjusted or the wiper arm is damaged inside the box and it is not reaching the last pad, post #9 in the picture.

Multi-Step Potentiometer Diagram
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Unread 12-09-2015, 07:38 PM   #16
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Default Re: '02 DS fully charged, shudders, slow, & hot cables

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Originally Posted by Sergio View Post
Take the Multi-Step Potentiometer, pie shaped looking box connected to the throttle linkage apart.

The first resistor is bad, #26 in the picture, it should be around 910Ω 1/4 watt.

Throttle linkage either needs to be adjusted or the wiper arm is damaged inside the box and it is not reaching the last pad, post #9 in the picture.

Multi-Step Potentiometer Diagram
I do think my MCOR readings are strange. But I don't have the pie-shaped multi-step potentiometer. My controller is a Curtis 1204-410 which requires a 5k-0 Ohm MCOR.
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Unread 12-09-2015, 07:57 PM   #17
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Default Re: '02 DS fully charged, shudders, slow, & hot cables

Can You post a picture of what You have?

If You got 0L with an MCOR, it is definitely bad.

If You got 0L with an CVP (Continuously Variable Potentiometer), it is definitely bad.

The MCOR would be approximately 7kΩ - 1kΩ.

Your readings starting with 0L are typical of the V-GLide shape Multi-Step potentiometer with a bad/broken first resistor.
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Unread 01-09-2016, 01:42 PM   #18
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Default Re: '02 DS fully charged, shudders, slow, & hot cables

Commutator looks pretty well toasted.

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