Bad Boy Electrical

tricone65

Hello All, I have read through many pages but have not found answer yet. I'll describe best I can. I have a BB 2012 XT Bone Collector buggy. It is 48V, 4X4 full time, Open spool. It has Advanced D.C. motors, DA7-4009. It has SEVCON controller's, #633T45320. Has White Rodgers coils, type 586 120111, 48V D.C Cont., 1140 Rev A, I have a new set, 8 each, of CROWN batteries, Model No. CR-260, 6 V, AH Rating 260 (20HR, AH Rating 215 (5HR). Replaced the front motor.

Now for the problem I am having. The range is very short, riding fields and roads hunting. When driving and let off the pedal instead of regen back and braking it just rolls on. When going down a grade and let off the pedal it trips out power. I have to turn key off and then back on to regain power. Yesterday when it done it I looked at the controllers and both were flashing 3 green lights. I can turn key off and then back on, I hear the coils click and lights go solid green and we go on.

The other problem is when riding over bumpy terrain it seems to loose power and only be pulling off the from end. I open box and one controller is solid green and the other controller is blinking 3 green times. I can turn the key off and back on, hear the coils click, then will regain full power. I suspect that the reason I have short range is that the rear coil is shutting down and then the front motor is dragging the rear??

How do I find out what the 3 green blinking lights mean? How can I tell if it is the coils? I don't want to just through money away and change things that are not bad. I know the BB is not very well thought about and there is little information to be found. I would very much appreciate some help from yall. Some rally smart folks here on 12V electric carts. Thanks in advanced!

BGW

__________________
This advertising will not be shown in this way to registered members.
Register your free account today and become a member on Buggies Gone Wild Golf Cart Forum

sunoco

I beleive this is the manual for your controllers. Fault codes are on page 48

http://www.fsip.biz/Documents/Sevcon...%20Section.pdf

tonymac01

i have a 2008 bad boy buggie that has the xp-2118 motors and the sevcon controllers (633T45320) ive had wiring issues so ive decided im just going to part this cart out. the motors, contollers all are good call if you need parts 405-435-0563

tricone65

Sunoco - Thanks much for the manual!

tonymac01 - I may take you up after my diagnosis

I spent all day yesterday trying to find info. From Sevcon site I have learned that as long as there is a light on the controller it should be good. If you have 3 blinking lights it is mosfet problem. That problem leads back to open solenoids not sending power to controller as I understand. So, I have ordered 2 new White Rodgers solenoids. The other article that lead me to this was that over time the arcing will cause them to become weak and eventually not hold. This sounds like what is happening to me. They are now coming up on 6 years old, I think have severed their life. The BBB really is a good buggy, the problem is with the folks that have built them not lending any help to keep them going. I say SHAME on them!! They sure did not mind taking our money at purchase! I will let you know the outcome Friday night when have the new ones on and another pig expedition.

tricone65

Well the diagnosis was not right! Received the 2 new solenoids yesterday and installed. Was upbeat all week about it would fix but cart is still kicking the rear motor out and pulling off the front. At first it is pulling and then I can feel it kick out in just a very short distance. Took cart out hog hunting last night and run time was 1/4 of what it should have been. Back to the drawing board today with it.

tricone65

Well BBB guys I wanted to follow up on problems. After the install of solenoids and not fixing problem it was off to the dealer. I dropped it off 2 weeks ago and the call came in that the rear controller was bad. Ordered another controller after negotiating a decent price and it was installed. The shop called and they have the rear motor and controller dialed in and working. The problem now they tell me is the front controller is getting low voltage and dropping out. Had not seen anything wrong with the front in past. They say that voltage is dropping from 48V to 42V and solenoid is dropping out. I would like to know if anyone has heard of the next thing they are doing.

They tell me they are putting the batteries in some kind of charger that puts a continuous 6V on the batteries for 3 days. That's right, 3 days straight! They tell me this will bring the 14 month old batteries back up??? Have any of yall ever heard of such? After this is done they will retest the front.

ThreeCW

Here is a recent discussion with a link to a video on the FSIP battery regeneration system. Perhaps your repair shop will be doing something similar?

http://www.buggiesgonewild.com/elect...eneration.html

Let us know how it works out for you if you go ahead with the battery regeneration.