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Old 06-23-2017, 09:36 AM   #1
bcontento
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Default Speed/Torque help & unusual "power switch" setup

I have an '86 DS 48v that seems to be lacking in both speed and torque. Flat line speed is a bit lacking and hill climbing is really weak. I've read a bunch of things about the dynamic brake solenoid, field shortening (I think that's what it was called), etc. but I'm not really sure where to start. I'm new to carts in general. I've attached some photos of what I'm working with.

I installed a voltage gauge in the circuit and after a full charge, it shows right around 50v so I think the batteries are taking a charge ok. I haven't taken them out and load tested each individually. Is that something I should do? Easiest method for doing it in place?

If the batteries are not the culprit, where should I start? Should I replace the 5 main solenoids and the coils/resistors? clearly they have some age to them. Do they deteriorate with age or do the either work or not work?

There is one oddity to this cart installed by the PO. There is a toggle switch he mounted and as he described it to me, it's purpose was to have a low-speed (less voltage) and a higher speed (more voltage) mode. I have no idea what it does, but it certainly doesn't do anything noticeable however, after just reading a little something about field shortening with a switch, is it possible that's what he did?

In the photo, can someone identify the solenoid all the way to the left of the main 5 solenoids (with the red and yellow lead)? It seems out of place doesn't it?

Thanks very much for the help!




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Old 06-23-2017, 09:42 AM   #2
scottyb
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Default Re: Speed/Torque help & unusual "power switch" setup

Not a 1996 48v. 1986 36v maybe.

PS
photo format all wrong this discussion board and makes post really hard to read.
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Old 06-23-2017, 09:59 AM   #3
bcontento
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Default Re: Speed/Torque help & unusual "power switch" setup

fixed the photos. hope that helps.

Missed-typed '96 for '86 (fixed that as well), but it's definitely 48v. 6x8v batteries and a 48v motor in it
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Old 06-23-2017, 10:27 AM   #4
jakesnake27
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Default Re: Speed/Torque help & unusual "power switch" setup

You've got a bit of a frankencart there. That old toaster oven drive system is not designed for higher voltages, and things will overheat. I would say your best bet is to upgrade to a solid state 48v system, especially since you've already got the batts and motor for it. Do you have a 48v charger?
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Old 06-23-2017, 10:32 AM   #5
bcontento
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Default Re: Speed/Torque help & unusual "power switch" setup

Quote:
Originally Posted by jakesnake27 View Post
You've got a bit of a frankencart there.
Yes, I have a 48V charger.

That's kinda what I thought. Can you provide a link/info on what is involved in upgrading to a solid state system? Actually, I just found something. That conversion is way out of my price range. Are there some better (cheaper/easier) options that I can address?
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Old 06-23-2017, 11:57 AM   #6
NoleFan4Ever
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Default Re: Speed/Torque help & unusual "power switch" setup

Quote:
Originally Posted by bcontento View Post
Yes, I have a 48V charger.

That's kinda what I thought. Can you provide a link/info on what is involved in upgrading to a solid state system? Actually, I just found something. That conversion is way out of my price range. Are there some better (cheaper/easier) options that I can address?
Did you check Revolution Golf Cars - David Hicks or Carts Unlimited - scottyb? They would be you best source for quality, price and support......

They are listed under the Site Sponsors link.
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Old 06-23-2017, 12:16 PM   #7
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Default Re: Speed/Torque help & unusual "power switch" setup

Quote:
Originally Posted by bcontento View Post

There is one oddity to this cart installed by the PO. There is a toggle switch he mounted and as he described it to me, it's purpose was to have a low-speed (less voltage) and a higher speed (more voltage) mode. I have no idea what it does, but it certainly doesn't do anything noticeable however, after just reading a little something about field shortening with a switch, is it possible that's what he did?

yep

In the photo, can someone identify the solenoid all the way to the left of the main 5 solenoids (with the red and yellow lead)? It seems out of place doesn't it?

yep it is the solenoid for field shortening ... far passenger side (with yellow 7 red cables
you throw the switch when moving and it dumps all available power to motor

you have a 1986 36v cart converted to a 48v cart
it will only go so fast and not a hill climber

and 48v will burn up things eventually
best to upgrade it to a controller cart
i'm sure someone has a link to that web site that has them
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Old 06-23-2017, 12:57 PM   #8
bcontento
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Default Re: Speed/Torque help & unusual "power switch" setup

ok so if the switch for field shortening is ON before getting up to speed, that would be the reason the startup torque and giddy up feels lacking, yes?

If everything was upgraded to 48v (motor, batteries, solenoids), what would get burned up and be problematic?

Thoughts about the dynamic brake controller being part of the problem? Best way to eliminate that issue (bypass, remove, etc)?

thanks guys!
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Old 06-23-2017, 01:57 PM   #9
Sergio
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Default Re: Speed/Torque help & unusual "power switch" setup

You don't have a dynamic brake anything since there is no Controller.

If the Field Weakening Solenoid is ON when You try to start the cart, You would likely not even move, just turn the motor into a toaster oven.

Make sure all of the 5 solenoids are closing and eliminating the coils from the system as that will cause a huge lack of torque.
Stop at the bottom of the hill and wait until the resistor coils are cool enough to touch them.
Press the go pedal all the way down quickly and drive up the hill.
Stop at the top of the hill and check if any coils are red hot.
If they are, you have Solenoids that are not closing and the resistor coils are reducing your power.
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Old 06-23-2017, 02:05 PM   #10
bcontento
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Default Re: Speed/Torque help & unusual "power switch" setup

Quote:
Originally Posted by Sergio View Post
You don't have a dynamic brake anything since there is no Controller.
OH!

I'll try that test out this weekend. Thanks.
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