Throttle issue?

[cheapjeep2]

99 Club Car series... The cart lurches and cuts out on power, when there is no load on the cart, there is no problem, with the tires up in the air cart runs just fine, but when you put a load on the cart it falters. Verified no motor issues, not transaxle related, test batteries and found one for a fact that was bad. Drove with volt meter on the cart and totally saw the battery dropping down to 3 volts or so, thought we had found our culprit, replaced the battery with a new one made sure pack was charged and there is no change. Owner said previous shop tested with their motor to rule it out, and also verified their controller good, only thing I can think of is a possible throttle issue or could the solenoid be dropping out?

[cheapjeep2]

Ok I need some help...I have gone through everything on this cart and still cannot find the problem.. Here is what I have done..

1. New f/r switch, verified micro switches n the f/r
2. Found and replaced a bad battery, all batts are holding loads
3. Ohmed out the throttle at the controller, it is a 5k-0 throttle, ohms out perfect through entire range with no drop outs
4. Ohmed out the motor, zero shorts, a1-a2 continuity, s1-s2 continuity, no continuity anywhere else.
5. Jump solenoid main power terminals
6. Tested diode
7. Solenoid activation circuit is good, solenoid not dropping out, also jumped negative side of solenoid to -48v pack, no change.
8. no shorts or frays in any power cables.

Again it runs and then it is likes the controller stops putting out power and it cuts out goes cuts out goes, and it only does it under load, at this point I think it is the controller.

Help any ideas on what I am missing or is there something that you see that I have not tested?

[cheapjeep2]

Sorry double post

[cheapjeep2]

Bump. help....

[TahoeDawgZ71]

I agree with you. I think the controller is the culprit. I've seen this before.

[cheapjeep2]

Originally Posted by TahoeDawgZ71

I agree with you. I think the controller is the culprit. I've seen this before.

Thanks Dave

[cheapjeep2]

WOW, what a night mare... I found it after an totally exhaustive search that involved two controllers a new forward and reverse switch and much, much more...

Even started a different thread about the AllTrax... http://www.buggiesgonewild.com/elect...red-light.html

Take a look at the picture... The owners son put in a different key switch used Wood screws, the power cables on both key switch lugs were loose, and that is why it would never have a problem when testing in a standing state and it would only act up while driving, the vibrations would shake the connections, and this is also why I could never find the problem cause I did have all the right voltages in every single test I did... ugh, what a nightmare.

[TahoeDawgZ71]

Wow..... Been there buddy. Don't feel alone. I've had stuff haunt me so many times and it almost always ends up being something like this.

[Stevegrmich]

. . . owner's son not very mechanically/electrically inclined . . .

[anix]

Been there too. Worked on cars for better than 30yr. Worked on them before they had computers all way through port an direct injection systems. Seen a lot of gremlins (not talking about American Motors lol) but electrical problems can make you pull your hair out.