1995 DS dies after short drive

[Timscarts]

I’m working on a 1995 48 volt DS (A9536) that cuts out after about 100 feet, let it sit a few minutes and it goes a few feet, let it sit an hour and it goes another 100 feet. Charged batteries, same thing. Swapped out the motor thinking the motor was shorting out and overheating controller but that didn’t change. Battery pack reads 50.4, solenoid will click even after it stops. It had the black box potentiometer on the frame under the floor, I did a mcor4 conversion and that made no change. Any ideas? I’ve got myself doing what I hate to do, replacing what’s not needed.

[cjpenny89]

It could be the Solenoid dropping out just because it clicks doesn't mean it is pulling in the big lugs on the solenoid passing voltage to the controller. When it does this put a jumper across the big lugs on the solenoid and see if the cart goes if it does the solenoid is bad. If not sounds like your controller might be the problem. If you find out that is the problem I do have a controller if you need one.

[CP241]

How old are the batteries? What’s the battery voltage while it is moving/driving? Resting voltage and loaded voltage are completely different things. A bad battery can read good while at rest but drop to nothing when you load it.

If the pack voltage is 50.4 and that’s fully charged it would also indicate a battery issue.

[cjpenny89]

CP241
you are correct I had that same issue on my current project. I had 50.7 volts and went to move it and the cart would shutter and move 10 feet and then not go. I found when I load tested the batteries I had one battery go to zero volts under load. replaced that battery and the cart was fine.
Good call on that!

[Timscarts]

I jumped the solenoid, no difference still cuts out. Checked batteries under load, drops to about 47 volts at take off and slowly comes up to 48-49 when at full speed then cuts out. Load tested all the batteries and they seem fine. I’m thinking the controller is on its way out. Batteries are 4 years old.

[Timscarts]

It’s fixed and I’m embarrassed I didn’t follow the wiring more closely, the connection from the black box potentiometer on the frame to the wiring harness was corroded. It’s under the forward/ reverse switch, cut the connector out and connected the wires together with heat shrink weather proof connecters and it’s good as new. Thanks for the help.

[CP241]

Good find. Glad you got it sorted

[cjpenny89]

persistence paid off good job finding that!

[billyvray]

I've got a similar-seeming problem with my 97. Potentiometer resistance gave odd readings when I tested at the wiring to the controller. I removed the Pot and resistance is perfect tested on the lugs.

<heavy sigh> I guess I need to start pulling the wiring back. Thanks for posting your solution.

Bill

Originally Posted by Timscarts

It’s fixed and I’m embarrassed I didn’t follow the wiring more closely, the connection from the black box potentiometer on the frame to the wiring harness was corroded. It’s under the forward/ reverse switch, cut the connector out and connected the wires together with heat shrink weather proof connecters and it’s good as new. Thanks for the help.