RXV is “surging” ??

[Finnster]

I have a 2011 RXV. It was acquired used. I have brand new Trojan batteries, 4-12v. I have replaced the motor brake being very careful to follow the service manual instructions. It’s an OEM brake….not the HD one.

Here is the issue, in tow mode it still grabs and releases intermittently. When I drive it, the power surges…..like I am fluctuating the throttle pedal…..it’s very intermittent. The brakes grab really hard.

My next step is to try replacing the solenoid….I hope that is the issue and not the controller. It has the Danaher Controller in it.

Could it be a bad controller?

I’m hoping it’s a solenoid issue.

I’m new to the AC type RXV….my last cart was a TXT from the 90’s and was simple and rock solid.

[rngilliland]

Make sure all your connections are snug and clean. I would loosen the motor brake until the bolts are just loose. Then flip the tow switch a few times leaving it in tow. Make sure you hear and feel the brake release. Tighten the bolts until the lock washers are compressed and then just a little more. If you have a torque wrench don't tighten the bolts more than about 40 in/lbs. The brake has to be released when the bolts are tightened to make sure the brake is aligned. As long as they aren't falling out I think too loose is better than too tight on the brake bolts.

If you install a new solenoid make sure not to twist the terminals when you tighten the nuts.

[Finnster]

Tks….good thoughts. I did tighten the brake bolts to 50 in lbs with a good torque wrench…..service manual said 62 in lbs (I think) but I went on the looser side. BTW, it was doing this when I got it but the batteries were 10 years old and the cart had been abused.

[JBERGER]

Do you have a good voltmeter that you can check the battery voltage when it's surging?
When I had the Danaher controller, mine would sometimes act similar when the battery was full and I was rolling down a long hill. It appears that it was bouncing between regen flowing into the battery and being dumped to the resistor.