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Unread 10-22-2009, 12:50 PM   #1
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Taylor-Dunn
 
Join Date: May 2009
Location: Southern California
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Default Carryall VI Jerking Start problem

Hi all, greetings from So. California.

I am working on a CC Carryall VI J9937 48v. Push on the accelerator and after the solenoid clicks the cart jumps to full speed both when in forward or reverse. Not very safe. It has what looks like the "Potentiometer with gray plug." listed in the catalogs as "OEM #1017392-01" or "5729" This part appears to have been replaced sometime in the past and they had in their junk parts box, parts from the old device. Linkage is ok everything is tight and moves smoothly.

Does anyone know if the "jumps to full speed" symptom is typical of a failed Potentiometer?

I can test the Potentiometer at the 3 pole plug but what should I see?
What ohm level would indicate a failed pot?
Is there another explanation for the "jumps to full speed" symptom?

Any help would be appreciated.
Thanks, Phil.
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Unread 10-23-2009, 09:58 AM   #2
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Default Re: Carryall VI Jerking Start problem

Just a guess ,
there are 2 types of Potentiometer those which go from 5K-0 ohms.
And those which go from 0-5k ohms.
Make sure yours matches the controller input requirements.

Also read this - Motor controller and Motor match?
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Unread 10-23-2009, 10:02 AM   #3
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Default Re: Carryall VI Jerking Start problem

#5729 lists for about $275 ... So they may have tried to replace it with a standard curtis pot. Not impossible to do but, they may have gotten the wrong pot.... there are 0-5k and 5k-0... The wrong one would result in the problem you describe.
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Unread 10-23-2009, 10:49 AM   #4
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Default Re: Carryall VI Jerking Start problem

To BGW
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Unread 10-23-2009, 11:09 AM   #5
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Taylor-Dunn
 
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Default Re: Carryall VI Jerking Start problem

Thanks Guys for the responses.
The crew who use this cart claim that the cart acceleration pattern was normal. Then changed to full speed whenever the solenoid kicked on. It quit working and they asked me to fix the "cart won't work problem" which turned out to be a burned out cable on the F/R switch. When I asked about the Full Speed Start problem they said that they would work with that because they needed the cart working. But now after a month or so it is a safety issue.

Since we are talking about resistance in the Pot 0-5K controlling speed, would poor connections on the control circuit wires give a higher ohms and produce this full speed problem? The control circuit wires on this cart look rough and other CC Carryalls at similar worksites have needed wires replaced due to corrosion, not caused by battery acid exposure.

The other comment re: which pot 0-5K or 5K-0 ohms. can you switch the connections the pot has 3 poles CW CCW and ?com. If these are incorrectly routed through the micro switches on the F/R switch can this cause problems? duh

Phil
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Unread 10-23-2009, 11:22 AM   #6
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Taylor-Dunn
 
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Default Re: Carryall VI Jerking Start problem

Hi again,
Does any one have a wiring diagram for a CC Carryall VI J9937?
That might help as on this cart there are several of the original wires that have been replaced when it was serviced in the past. Previous repair guy passed away so can't ask him any what did you do to that cart questions.
Thanks for the help and suggestions.
Phil
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Unread 10-23-2009, 11:46 AM   #7
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Default Re: Carryall VI Jerking Start problem

SOme of those pots can be opened up and changed. Have you tested your output yet??? Use the standard 95-96 diagram with your pot. It should be in the stickies at the top of this section.... I am almost certain they have the wrong POT. Please identify the unit.
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Unread 10-23-2009, 12:03 PM   #8
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Default Re: Carryall VI Jerking Start problem

Quote:
Originally Posted by scottyb View Post
SOme of those pots can be opened up and changed. Have you tested your output yet??? Use the standard 95-96 diagram with your pot. It should be in the stickies at the top of this section.... I am almost certain they have the wrong POT. Please identify the unit.
Agree let's get the output tested and get this wiresd correctly (if incorrect).
Then we'll see what else is grapping out
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Unread 11-05-2009, 11:40 AM   #9
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Taylor-Dunn
 
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Default Re: Carryall VI Jerking Start problem

Hi Everyone,
Thanks for responding to my question. Jacked up the cart. I connected the 3 pin connector to a good pot and got the correct slow to fast response from the cart. Then it took a week and half to get the part (POT HOUS C-260), cost $143. There is a lot of hardware to remove, in sequence to get the pot box out. The surprise, not really, is that this box was HALF FULL of dirt, sand, the terminals of the pot were buried. Looks like when the cart is operated in wet-rainy conditions water also gets inside. The pot box has two wire ports that need a touch of silicon sealant, but the shaft going through the box would still allow some finer materials and liquid into the box. So would silicon on the lower right side just make the box a pond?

Started working on this one, on jack-stands, what a pain, no clearance. Talked to the owner and half an hour later a forklift shows up and I got to finish the install work standing up! There are two important adjustable slots, one for the foot throttle position, the other more important slot adjusts the turn on microswitch and pot position. That adjustment worked best in the middle of the slot. Lowered the cart, reconnected batteries, plugged in the connections. Replaced the seat, turned the key, depressed the throttle, click and just a bit more throttle and it moves, nice slow start. Checks out, works well. Thanks for the help.
Phil
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Unread 11-05-2009, 04:49 PM   #10
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Default Re: Carryall VI Jerking Start problem

Hey Phil good job hanging in there until it worked and we always appreciate feedback
Hang around and Pay it Forward .
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