Reversing contactor crapped the bed already?!?

[Dela]

Originally Posted by scottyb

Good Call. I was going to suggest a shop diagnose the cart
Keep us posted we are all curious now.

Ok - so swung by the shop yesterday - findings so far are two 'bad' batteries. Pack is getting 90 minutes till total discharge but 5 and 6 batteries are reading 6.2 and 5.6.

The one reading 5.6 has a few accessories on negative - I should have run those to a fuse panel as the accessories are pulling from one battery mechanic thinks I have compromised the cells and cart is stalling when amps aren't sufficient.

The battery reading 6.2 is a battery that was tapped when a terminal melted off due to loose nut.

What are your thoughts here? Can this be the issue to intermittent stalls?

Replacing the two Trojan's - and hoping it resolves issue - will rewire fuse panel and accessories once I get it home.

[scottyb]

So the cart mechanic doesn't think there is anything wrong with the reversing contactor.

Tapping 12v off the battery pack by attaching accessories to one or two batteries creates an imbalance that cannot be rectified by recharging. Basically this imbalance causes the charger to overcharge the good batteries while the the 1 or 2 low ones remain low even when the charge is done thus perpetuating the problem over and over.
This combined with the 'repaired' terminal could be the cause of your intermittent problems especially if you saw the problem after the cart was run a little bit

[Dela]

Ok - so update as of now.

Replaced batteries - cart ran for two days and died again.

Just replaced solenoid and rewired completely to SW202 Reversing contactor

Cart ran right off the bat - pulled in garage, continued some small repairs..

CART DEAD - sat for a bit with foot on accelerator - CART RAN..

I am going NUTSSS!!!

What can it be? Do I need to just replace the controller at this point?

[Dela]

Controller reads full voltage when cart does not move - reads half pack in neutral

I did the ole' caveman bonk - and hit the controller with a hammer a few times -

CART RAN

Controller reads full pack at start runs to 0.00 at full throttle moving..

I have no option but to assume it's the controller at this point.

[Dela]

Just bought a SR48400 from ScottyB - Let's hope this is the end of it. I'm $1000 into figuring this out by now

UGH!!

[Dela]

and now - Scotty out of office till the 8th... I can not win... just can't