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Unread 09-13-2016, 09:03 PM   #1
Getting Wild
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Join Date: Aug 2016
Location: Georgia
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Default Power Surging?

Looks like my gremlins are back.
Get on the cart today and ride down the street in front of house. Turn around at the stop sign to go back toward house when cart starts to slow down, then take off, then slow down to a crawl. I'm keeping the pedal fully pressed the whole time. It crept back into the yard then took off again, then slowed down to a crawl. Like intermittent power or maybe limp mode?
Keep thinking the solenoid contacts are causing my problems, so I pull in to shop and remove solenoid to clean connections thoroughly. one of the large studs was a little loose. Put it all back and it's still acting up. Runs normal a few seconds then crawls, then full power again.
This is a new problem. Every time I think I've got all the gremlins out, some new issue arises (in the month I've had it).
Have read the jerky problems with MCORs, but it wasn't jerky. More like power surge then very low power/crawl. This started just after full charge if it matters. Pack was 51.5V after overnight rest. Finally got the charger working (post about this a few days ago)
Make any sense?

'02 DS Series 48V New batteries
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Unread 09-13-2016, 10:30 PM   #2
Dawg Gone Wild
 
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Default Re: Power Surging?

Unplug the Yellow and Green 16 gauge wires from the controller located on pins 2 and 3. They have female blade connectors on them. Insert the leads of your multimeter into the ends of those wires. Set it to 20k ohms and put the F&R lever in forward. Monitor your mcor frequency. Put the pedal on the floor and see if the resistance fluctuates. If it does, it's an MCOR problem. If it doesn't, it's likely a controller issue. You should see around 1100 ohms at full throttle and it should hold as steady as your foot. If your foot is still while holding the pedal down, the frequency shouldn't move either.
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Unread 09-14-2016, 05:54 PM   #3
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Default Re: Power Surging?

It's steady at 1140 when pedal is fully depressed. 7900 at rest, pedal up. No fluctuations.
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Unread 09-14-2016, 08:52 PM   #4
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Default Re: Power Surging?

Does this indicate a faulty controller?
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Unread 09-14-2016, 10:13 PM   #5
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Default Re: Power Surging?

Quote:
Originally Posted by Ribber View Post
Does this indicate a faulty controller?
Yes. If the throttle input does not fluctuate, but the cart speed does, there's an issue with the controller.
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Unread 09-18-2016, 09:04 PM   #6
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Default Re: Power Surging?

I changed out the controller, fnr switch, & solenoid, all known working from a member here.
Now, I have a new problem. Cart took off initially out of shop in reverse. Nothing in forward. I have unplugged/plugged all connections twice and double checked, but still nothing. Even in reverse, sometimes it won't move. Solenoid clicks every time. I was careful to wire back just like it was and took before pictures.
I'm almost ready to throw in the towel. I've been working on this cart for over a month and I can't seem to get it running consistently.
I'm posting pics of the new controller and fnr switch, if someone can look and see something wrong. Otherwise, I'm going to take my whooping and take it a local shop to see if they can find what's wrong. It's probably something simple that i'm overlooking, but I'm burnt out on it.
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Unread 09-18-2016, 09:09 PM   #7
Dawg Gone Wild
 
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Default Re: Power Surging?

Take a picture of the connections on the bottom of the F&R switch. Should be a white wire there.
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Unread 09-18-2016, 09:26 PM   #8
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Default Re: Power Surging?

Quote:
Originally Posted by TahoeDawgZ71 View Post
Take a picture of the connections on the bottom of the F&R switch. Should be a white wire there.
I can take a pic tomorrow, but there is a white cable that's connected on underside of switch. And also a blue cable.
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Unread 09-19-2016, 08:30 PM   #9
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Default Re: Power Surging?

I've tried every combination on the green, black, & white wires on furthest rear microswitch on FnR. I can either get forward or reverse, not both. Is there something I'm overlooking?

Also I noticed on a wiring diagram from here, that it shows a green wire and white/black wire going to solenoid. I don't have those at the solenoid.
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Unread 09-19-2016, 10:00 PM   #10
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Default Re: Power Surging?

TTT. Need help
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