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Unread 05-17-2019, 10:33 AM   #1
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Default Old cart to new owner - trouble shooting

Hey all, I have been reading (lurking) these forums for awhile and trying to do some repairs to a "new to me" cart.

The cart is a 2000, late model (46th week). It had no batteries when I got it, so I found a used set that is a few years old that tested 51+v when I put them in.. I still need to set up the load test..I know this is a factor especially with 3 yo batteries...and will get to that later this weekend.

When I turned the key on it immediately (without hitting the pedal) "clicked" the solenoid and speed control started whining.. So, through these forums I figured it must be getting some power some how..and checked the v glide and sure enough..that was out of adjustment, resting on the 2nd and 3rd pad.. Fixed that adjustment and that noise went away..all works as it should in that sense.

Went for a little rip..top speed 10mph, but taking off the line has zero torque..if you will...and will not climb anything steep. Step on the pedal and it takes it's time to start moving..

I have ridden in 100's of these carts and know it should be more powerful than that.

Could this simply be batteries? It runs very smooth at 10mph and doesn't slow down...drove for a 1/4 mile or so and zero issues. top 2/3rds of the pedal work as it should..just a low top speed and no torque.

While typing this out...I wonder if the bottom pads of my vglide have bad wires? Does this happen...if they weren't working, then I wouldn't have any torque. (I think?)

Anyway, I will keep things updated here and looking forward to any comments!
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Unread 05-17-2019, 10:44 AM   #2
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Default Re: Old cart to new owner - trouble shooting

I'd start by hooking up a meter to the battery pack and watching the voltage as you drive. If it's a 48V pack and everything else is stock, it shouldn't drop below 45V on a fresh charge.

I had a 48V Carryall, it took me a good 5 miles of straight driving on it before it would even drop below 48V under load. My DS drops to about 46 under load, but it's pretty heavily modified, runs about 30 mph.

Does this cart have toaster coils or a controller? if it's 48V it should be a controller cart, but not sure if you put 48V batteries in a 36V toaster (you'd want to replace the 36v solenoid with a 48v solenoid if so). If it's a toaster cart, one of the coils may be burned out or broken. v-glide may be melty. could be a lot of things, but nothing you wouldn't be able to chase down with a meter.
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Unread 05-17-2019, 11:59 AM   #3
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Default Re: Old cart to new owner - trouble shooting

Quote:
Originally Posted by CP241 View Post
I'd start by hooking up a meter to the battery pack and watching the voltage as you drive. If it's a 48V pack and everything else is stock, it shouldn't drop below 45V on a fresh charge.

I had a 48V Carryall, it took me a good 5 miles of straight driving on it before it would even drop below 48V under load. My DS drops to about 46 under load, but it's pretty heavily modified, runs about 30 mph.

Does this cart have toaster coils or a controller? if it's 48V it should be a controller cart, but not sure if you put 48V batteries in a 36V toaster (you'd want to replace the 36v solenoid with a 48v solenoid if so). If it's a toaster cart, one of the coils may be burned out or broken. v-glide may be melty. could be a lot of things, but nothing you wouldn't be able to chase down with a meter.
Yeah, my plan is to load test this weekend after a full top up charge. It is a 48v cart with a controller? I think..lol It has one resistor coil.
A thought that occurred to me this morning while trying to get some real work done, was that maybe the wires on the bottom couple of pads in the vglide system were corroded and not actually working...could this also be a factor?
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Unread 05-17-2019, 12:14 PM   #4
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Default Re: Old cart to new owner - trouble shooting

That would be a Regen2 cart. You should have a speed switch on the motor. Disconnect that as a test and see if it does any better. I know on the Regen1 it would not put you in Limp as in the IQ carts, and I ~believe you could on the Regen2's also....
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Unread 05-17-2019, 12:59 PM   #5
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Default Re: Old cart to new owner - trouble shooting

Quote:
Originally Posted by NoleFan4Ever View Post
That would be a Regen2 cart. You should have a speed switch on the motor. Disconnect that as a test and see if it does any better. I know on the Regen1 it would not put you in Limp as in the IQ carts, and I ~believe you could on the Regen2's also....
I will look this up and try that! Thanks
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Unread 05-17-2019, 05:57 PM   #6
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Default Re: Old cart to new owner - trouble shooting

So, with a quick test, batteries at full charge..50.5v...jump on and load test, from zero to full speed a drop to about 49.5ish and held for 5 min or so of random driving.. at rest, back up to 50.5.

Speed switch was previously disconnected.

My next look will be back into the v glide and check out the lower speed pads/wires.

Can't wait for this to get working properly so this can turn into a mod thread...lol
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Unread 05-18-2019, 12:12 PM   #7
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Default Re: Old cart to new owner - trouble shooting



Going over the multi step pot....I noticed the wear marks.. I presume these mean that the pads aren't meshing flat. Trying the adjustment today to level that out and see if it removes the slow torque issue.

Possibly motor brushes next?

-edit- can anyone see the photo?

Last edited by Clarkwho; 05-18-2019 at 12:14 PM.. Reason: added photo
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Unread 05-18-2019, 05:05 PM   #8
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Default Re: Old cart to new owner - trouble shooting

Ok, so, leveled out the pad in the v.s.p. but that didn't help my zero torque issue.

Kids have been running around in the cart for about an hour or so and batteries are still 49.5, but one thing that did happen is a "stall". No power... a little love tap to the controller box and instant start again (still zero torque)..a few minutes later, same stall. Let it rest for a bit and away it went...kids are out riding again.
When I bought it..I was told there may be an issue with that controller.. from all my reading on here..I am thinking the only fix is the upgrade to alltrax?

I read in another forum there was one taken apart and fixed...anything more on that aspect? does anyone know a rebuilder?
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Unread 05-18-2019, 05:44 PM   #9
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Default Re: Old cart to new owner - trouble shooting

Quote:
Originally Posted by Clarkwho View Post

-edit- can anyone see the photo?
Nope
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Unread 05-18-2019, 05:47 PM   #10
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Default Re: Old cart to new owner - trouble shooting

That is a Regen2 controller and little to no parts for them. You use to have to convert to an IQ harness but now you have an Alltrax alternative with their XCT line.

And yes, it does sound like a controller issues.
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