Very custom cart needs some troubleshooting help.

mandalore01

Hello All,
I've been using the awesome wealth of knowledge on this board to help me with my "out of this world" customization of an old 88 Marathon cart. Everything stock has been removed minus the body and tires, and I installed a new curtis 1268 Sepex system + D&D motor. Also bumped it up from 36v to 48v with brand new batteries.

Yesterday I fired it up for the first time to test my wiring. Forward ran in both low and full speed, however I didn't get anything in reverse...not even a solenoid click. Checked the voltage across both sides of the direction switch, and it measured 49.1 volts.

I'm using both a brand new Curtis 1268 controller and relay/servo system from Bholinger Inc , as well as a custom high speed/high torque motor from D&D Motors. Harnesses for the controller came pre-wired from , so it was basically plug-and-play.

Any help would be much appreciated!

BGW

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JohnnieB

Please explain the items highlighted in greater detail. IE: Do you have a two speed capability of some type? What is a relay/servo system and what is it used for?

Also, what are you using for a throttle, Pot box, ITS or something else.

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Solenoid not clicking in reverse:

Check the voltage on J1 Pin 10 & 11.
Should be pack voltage on Pin-10 and Zero on Pin-11 in Forward and Zero on Pin-10 and pack voltage on Pin-11 in reverse.

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What model D&D?

mandalore01

Thanks for the quick reply!
1. Yes, the controller was programmed for 2 speeds. The vehicle is a 1 of a kind set prop, and a slow speed was programmed in for parade use.

2. The solenoid is the golf cart solenoid, and is a Curtis/Albright 400A.

3. I bought the pre-connected harness along with the controller from Bohlinger.

4. I'm guessing the Curtis FP6 is a potbox, the booklet for it says 5k pot.

Measured voltage and here's the odd thing. J11 (gold wire on the direction switch) seems to be going forward instead of reverse. J10 (green wire on the switch) does nothing, when it should be forward. Voltage on J11 is 48.8V, and I've attached pics.

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mandalore01

Motor model is ES-9B-50

JohnnieB

1, 2, 3 & 4: Thanks, I've got a handle on your drive system now.

Your F/R switch is miswired.

If the Green wire goes to J1 Pin-10 (Forward) it should not be on the center terminal on the F/R switch.

As shown in the picture, the Green wire is connected to the Red/Wht wire, so the cart operates in Forward. When toggle is flipped to other side, the Yellow wire (Pin-11) is connected to the Green Wire (Pin-10), so no direction is selected and your cart does nothing.

Transpose the Red/Wht and Green wires on the switch and you should be in business.

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Basically, the Red/Wht wire has 48V on it and SPDT switch connects the voltage to either the Green wire or the Yellow wire to tell the controller which way to send the current through the field windings.

DoorKicker

Question: was this done for convenience or to prevent damage?

I use my cart in parades also, and don't want to damage it if this is something I should be doing...

Thanks

kgsc

Curtis 1268 is a pretty slick controller with tons of options but takes some tweaking to make it 100%.. We built a cart for similar reasons, low speed for hunting and high speed for the street.. You deal with Steve ?

mandalore01

I'll head down to the shop this week and switch those wires around. Hopefully that's all it is. :)

mandalore01

It was done to prevent damage and the need to use the brakes in parades or at events. For all intents and purposes, this vehicle no longer looks anything like a golf cart. In fact most people are shocked when I tell them it started off as a golf cart, lol.

mandalore01

Yep, dealt with Steve. He was extremely helpful, as was Vic over at D&D.