Little power and dim lights

rnuckols · 03-22-2014, 06:06 PM

Last summer I upgraded my controller to 500a Alltrax, replaced the motor with a switchable one from EMP, and put in a HD solenoid. It was a huge improvement and everything seemed to be going well for a while. Then I started smelling something burning and I noticed the lights being much dimmer. I ordered a 4 gauge wiring kit from Carts Unlimited thinking this might solve the problem, but it didn't. I ordered a HD forward/reverse switch from them again, thinking that might be the problem, but still no luck. It runs but very, very weak and the lights barely burn. I don't know what else to try. Any suggestions?

radioman · 03-22-2014, 07:00 PM

Check for loose connections. Measure the battery voltage and check connections for elevated heat. If you smell something burning feel around and find out what is getting hot without getting burnt. A infrared hand held temperature sensor would help.

rnuckols · 03-22-2014, 07:57 PM

I tried checking the voltage and the batteries showed 36 volts. Since I changed out the F/R switch it doesn't seem to be getting hot, but I haven't driven it very far or long due to such poor performance.

Sir Nuke · 03-22-2014, 08:00 PM

You said that the battery pack shows 36v.....is that all? as in reality, that's dead. the pack is at 50% SOC. A filly charged 36v pack should be reading 38.3v..... you need to be charging them.....no wonder the lights are dimming

rnuckols · 03-22-2014, 08:06 PM

Sorry, I just put it on there again and it was 77.7. I must have done something incorrectly. Also, the gauge on the dash shows the charge as nearly full.

JohnnieB · 03-23-2014, 09:55 AM

Quote:

Originally Posted by rnuckols

Sorry, I just put it on there again and it was 77.7. I must have done something incorrectly. Also, the gauge on the dash shows the charge as nearly full.

If it is a LED bar-graph gauge, they lie more than some politicians, so do yourself and your batteries a favor and replace it with a DVM type gauge.

I suspect you meant to type 37.7V, which is still only 85% SoC.
Attached is a Voltage vs SoC chart. The voltages are measured after the batteries have sit for 12 hours after the charger shuts off.

Also, each battery should measure 6.37V and all six should be within 0.1V of each other.

rnuckols · 03-23-2014, 10:33 AM

JohnnieB, I think the charge was part of the problem. I charged it overnight and I just went down the street in it, and it seemed to perform like it used to. The strange thing is, the gauge on the dash showed that it was only down 1 bar. I still have my issue with the lights though. They are still dim. What could be causing this?

JohnnieB · 03-23-2014, 12:52 PM

Like I said, those gauges are unreliable.

How do you get the 12V for your lights?
Tapped main battery pack, separate 12V auxiliary battery or voltage reducer.

rnuckols · 03-23-2014, 02:05 PM

I believe it goes to the battery, not a voltage reducer.

JohnnieB · 03-23-2014, 04:07 PM

Without knowing exactly how the lights get 12V power, all I can suggest is check the wiring.

03-22-2014, 06:06 PM	#1
rnuckols Not Yet Wild Join Date: Mar 2014 Posts: 5	Little power and dim lights Last summer I upgraded my controller to 500a Alltrax, replaced the motor with a switchable one from EMP, and put in a HD solenoid. It was a huge improvement and everything seemed to be going well for a while. Then I started smelling something burning and I noticed the lights being much dimmer. I ordered a 4 gauge wiring kit from Carts Unlimited thinking this might solve the problem, but it didn't. I ordered a HD forward/reverse switch from them again, thinking that might be the problem, but still no luck. It runs but very, very weak and the lights barely burn. I don't know what else to try. Any suggestions?
rnuckols Not Yet Wild Join Date: Mar 2014 Posts: 5

03-22-2014, 07:00 PM	#2
radioman Gone Wild Join Date: Jan 2014 Location: South Georgia Posts: 1,120	Re: Little power and dim lights Check for loose connections. Measure the battery voltage and check connections for elevated heat. If you smell something burning feel around and find out what is getting hot without getting burnt. A infrared hand held temperature sensor would help.

03-22-2014, 07:57 PM	#3
rnuckols Not Yet Wild Join Date: Mar 2014 Posts: 5	Re: Little power and dim lights I tried checking the voltage and the batteries showed 36 volts. Since I changed out the F/R switch it doesn't seem to be getting hot, but I haven't driven it very far or long due to such poor performance.
rnuckols Not Yet Wild Join Date: Mar 2014 Posts: 5

03-22-2014, 08:00 PM	#4
Sir Nuke Master of All Things Join Date: May 2013 Location: West Columbia, Texas Posts: 17,967	Re: Little power and dim lights You said that the battery pack shows 36v.....is that all? as in reality, that's dead. the pack is at 50% SOC. A filly charged 36v pack should be reading 38.3v..... you need to be charging them.....no wonder the lights are dimming

03-22-2014, 08:06 PM	#5
rnuckols Not Yet Wild Join Date: Mar 2014 Posts: 5	Re: Little power and dim lights Sorry, I just put it on there again and it was 77.7. I must have done something incorrectly. Also, the gauge on the dash shows the charge as nearly full.
rnuckols Not Yet Wild Join Date: Mar 2014 Posts: 5

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03-23-2014, 10:33 AM	#7
rnuckols Not Yet Wild Join Date: Mar 2014 Posts: 5	Re: Little power and dim lights JohnnieB, I think the charge was part of the problem. I charged it overnight and I just went down the street in it, and it seemed to perform like it used to. The strange thing is, the gauge on the dash showed that it was only down 1 bar. I still have my issue with the lights though. They are still dim. What could be causing this?
rnuckols Not Yet Wild Join Date: Mar 2014 Posts: 5

03-23-2014, 12:52 PM	#8
JohnnieB Techno-Nerd Join Date: Jun 2011 Location: West Virginia Posts: 19,654	Re: Little power and dim lights Like I said, those gauges are unreliable. How do you get the 12V for your lights? Tapped main battery pack, separate 12V auxiliary battery or voltage reducer.

03-23-2014, 02:05 PM	#9
rnuckols Not Yet Wild Join Date: Mar 2014 Posts: 5	Re: Little power and dim lights I believe it goes to the battery, not a voltage reducer.
rnuckols Not Yet Wild Join Date: Mar 2014 Posts: 5

03-23-2014, 04:07 PM	#10
JohnnieB Techno-Nerd Join Date: Jun 2011 Location: West Virginia Posts: 19,654	Re: Little power and dim lights Without knowing exactly how the lights get 12V power, all I can suggest is check the wiring.

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