Cart died... looking for direction

[derekbooth]

'96 36V DCS

Just dropped a Plum Quick Bandit in this a few weeks back. I have MAYBE 2 - 3 hours of pedal downtime on this since the ugprade. I've still got the stock solenoid and speed controller. Had some friends over last night for dinner and took my buddy out to show him how much quicker it is with the motor upgrade. Cart was fully charged. Cart took off quick and got up to top speed and within about 150 yards, just completely died. Lights still work. Reverse buzzer works. Checked all cables and seem to be just fine. Hill alert even seemed to be working when we were pushing it up my driveway (short, rapid beeps), but no forward/reverse movement. Doesn't sound like the motor is trying to do anything either.

With my limited (but growing!) knowledge, I'm narrowing it down to the controller or solenoid, but leaning toward the solenoid. How would I go about verifying?

[JohnnieB]

Sticky: at top of this forum.

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

Down load the two PDF files at the bottom of the page as well as the wiring diagram.

The one labeled "dcs.pdf" is one of the best troubleshooting guides I've ever seen and I've seen a bunch.

[scottyb]

Keep us posted

[derekbooth]

Battery pack reading is 37.3

All 10-PIN connector readings check out

I'm not sure I'm checking for continuity properly at the 4 PIN connector. I've got my Multimeter set to Resistance at the 200 position and pretty much no matter which way I put the red/black probes, I get a reading of 1 or -1.

With the key switch on, gear selector in forward and tow/run switch in the run position:

Reading from the battery side of the solenoid reads 37.3
Reading from the controller side of the solenoid reads 37.3

...safe to assume I need a new solenoid, yeah?

[scottyb]

Originally Posted by derekbooth

Battery pack reading is 37.3

All 10-PIN connector readings check out

I'm not sure I'm checking for continuity properly at the 4 PIN connector. I've got my Multimeter set to Resistance at the 200 position and pretty much no matter which way I put the red/black probes, I get a reading of 1 or -1.

With the key switch on, gear selector in forward and tow/run switch in the run position:

Reading from the battery side of the solenoid reads 37.3
Reading from the controller side of the solenoid reads 37.3

...safe to assume I need a new solenoid, yeah?

No. You are probably reading voltage through the resistor.
You can remove the resistor and recheck. Is the solenoid clicking when you press the gas?

[derekbooth]

In other words, disconnect the tow run switch and recheck?

This returns 37.4 on battery side and 34.6 on controller side. Pressing the accelerator causes the solenoid to click once and then motor begins to vibrate. But no forward movement.


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I am here: http://maps.google.com/maps?ll=33.687049,-117.245944

[derekbooth]

Update. I think I misread my initial test on PIN 5 of the 10 PIN connector. I'm only getting about 27v there with the pedal pressed down. 37.3 at the pack. The cart creeps forward very very slowly and rattles and vibrates quite a bit.


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I am here: http://maps.google.com/maps?ll=33.687043,-117.245944

[rabbitreborn]

what is the pack voltage with the pedal down? This sounds like a battery issue to me right now.....

[derekbooth]

Ignition on, cart in forward, pedal up 37v at pack and pedal down fluctuates around the 26's and 27's

I'm guessing this is bad news for at least one of my batteries :(

[scottyb]

Derek, repeat the voltage test with the meter connected to one battery, do this for each battery and you may find the one (or 2) that's crapping out.