Complete overhaul loosing my mind! 10V loss

khoff99 · 07-08-2009, 09:49 AM

I need some help guys, i've been on here before asking about high amp draws but here's my latest. I've redone a 92 ez-go w/a EMP high torque motor, new curtus 700 amp controller, h/d seloniod, h/d forward reverse switch, PB-6 pot box, 2/0 welding cable w/crimp ends, and my last draw was a full new set of trojan batteries. WTF would cause me to loose 10-12 amps from the battery to the motor? I upgraded from 36 to 48V and I have 50V across my pack, and 38V at my motor..... I'm about ready to shove the thing in the lake! It has amp draws of about 200 amp pulling a hill. I have about a 3V draw from the battery pack to the frame, but that's about it! HELP!

dougmcp · 07-08-2009, 11:26 AM

Sounds like a controller wiring problem.
There is a great trouble shooting manual on the Curtis website http://curtisinst.com/index.cfm?fuse...egory&catID=11
If that checks out give EMP a call, they're great.
Electrical Motor Products, Inc. Phone: 1-877-455-1599

khoff99 · 07-08-2009, 12:10 PM

That's just it.... It seems to be wired right and Chuck has already sent me a second motor with the same result! It did the same thing when I had it at 36V, it would drop to 28V or so.

dougmcp · 07-08-2009, 01:18 PM

It appears to me to be a controller or wiring issue. I would drill down on the test procedures using Curtis' test procedures to see what you have going on. If your not getting full voltage back to your motor with the pedal pushed down, it could even be a pedal switch problem, something wired to chassis ground or even a bad controller. Page 27 in the 1204/1205 controller manual is a quick way to determine your issues.

khoff99 · 07-08-2009, 01:24 PM

Yeah, i've went though those!! THAT'S WHY I"M LOOSING MY MIND!! lol, I have checked my pot switch and i'm getting a full 5K out of it. Do you know if I would hurt anything if I put a straight 48 to the motor? Just jump out the controller completely? This is the second controller as well. Do you think there could be a bad wire? I used old welding cable, but i don't think that it can go bad? When I used the drill down from curtis, it passed everything I had.

dougmcp · 07-08-2009, 03:09 PM

I'm out of constructive ideas. Maybe someone with more diagnostic skills can step up and offer some suggestions.

buckmanmike · 07-08-2009, 04:44 PM

If you have 50v going into controller and 50v coming out of controller but only 38v at motor it would seem the wire from controller to motor has a bad connection.
Check the voltages at each connection i.e. from pack(50v), to solenoid(50v), out of solenoid(50v), etc.

Nate · 07-08-2009, 09:57 PM

Which wiring diagram are you looking at? Can you post the exact link? Tell me where your black and red meter leads are being placed.

khoff99 · 07-09-2009, 04:25 AM

Ok guys, I have some new data! I tried again last night looking at the DC amp draw and Voltage. I have 38V in forward coming from S1 and A1 at the motor. When I put it in reverse and back up the hill, the meter starts out at 100+ volts and then drops to 42. I'm not sure if it has something to do w/the polarity when switched to reverse. I know it's physically impossible to have 100V but I just don't understand it? I have an autocad drawing that i've created for just this reason. I can e-mail a word file however it's kinda hard to read.

scottyb · 07-09-2009, 07:22 AM

Does the cart run okay? Did you check your meter and replace the battery?

07-08-2009, 09:49 AM	#1
khoff99 Not Yet Wild Join Date: May 2009 Posts: 54	Complete overhaul loosing my mind! 10V loss I need some help guys, i've been on here before asking about high amp draws but here's my latest. I've redone a 92 ez-go w/a EMP high torque motor, new curtus 700 amp controller, h/d seloniod, h/d forward reverse switch, PB-6 pot box, 2/0 welding cable w/crimp ends, and my last draw was a full new set of trojan batteries. WTF would cause me to loose 10-12 amps from the battery to the motor? I upgraded from 36 to 48V and I have 50V across my pack, and 38V at my motor..... I'm about ready to shove the thing in the lake! It has amp draws of about 200 amp pulling a hill. I have about a 3V draw from the battery pack to the frame, but that's about it! HELP!
khoff99 Not Yet Wild Join Date: May 2009 Posts: 54

07-08-2009, 11:26 AM	#2
dougmcp Gone Wild Join Date: Mar 2009 Location: Roseville, CA Posts: 2,757	Re: Complete overhaul loosing my mind! 10V loss Sounds like a controller wiring problem. There is a great trouble shooting manual on the Curtis website http://curtisinst.com/index.cfm?fuse...egory&catID=11 If that checks out give EMP a call, they're great. Electrical Motor Products, Inc. Phone: 1-877-455-1599

07-08-2009, 12:10 PM	#3
khoff99 Not Yet Wild Join Date: May 2009 Posts: 54	Re: Complete overhaul loosing my mind! 10V loss That's just it.... It seems to be wired right and Chuck has already sent me a second motor with the same result! It did the same thing when I had it at 36V, it would drop to 28V or so.
khoff99 Not Yet Wild Join Date: May 2009 Posts: 54

07-08-2009, 01:18 PM	#4
dougmcp Gone Wild Join Date: Mar 2009 Location: Roseville, CA Posts: 2,757	Re: Complete overhaul loosing my mind! 10V loss It appears to me to be a controller or wiring issue. I would drill down on the test procedures using Curtis' test procedures to see what you have going on. If your not getting full voltage back to your motor with the pedal pushed down, it could even be a pedal switch problem, something wired to chassis ground or even a bad controller. Page 27 in the 1204/1205 controller manual is a quick way to determine your issues.

07-08-2009, 01:24 PM	#5
khoff99 Not Yet Wild Join Date: May 2009 Posts: 54	Re: Complete overhaul loosing my mind! 10V loss Yeah, i've went though those!! THAT'S WHY I"M LOOSING MY MIND!! lol, I have checked my pot switch and i'm getting a full 5K out of it. Do you know if I would hurt anything if I put a straight 48 to the motor? Just jump out the controller completely? This is the second controller as well. Do you think there could be a bad wire? I used old welding cable, but i don't think that it can go bad? When I used the drill down from curtis, it passed everything I had.
khoff99 Not Yet Wild Join Date: May 2009 Posts: 54

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07-08-2009, 03:09 PM	#6
dougmcp Gone Wild Join Date: Mar 2009 Location: Roseville, CA Posts: 2,757	Re: Complete overhaul loosing my mind! 10V loss I'm out of constructive ideas. Maybe someone with more diagnostic skills can step up and offer some suggestions.

07-08-2009, 04:44 PM	#7
buckmanmike Gone Wild Join Date: Oct 2007 Location: Snellville, Ga. Posts: 1,304	Re: Complete overhaul loosing my mind! 10V loss If you have 50v going into controller and 50v coming out of controller but only 38v at motor it would seem the wire from controller to motor has a bad connection. Check the voltages at each connection i.e. from pack(50v), to solenoid(50v), out of solenoid(50v), etc.

07-08-2009, 09:57 PM	#8
Nate Gone Wild Join Date: Dec 2006 Posts: 679	Re: Complete overhaul loosing my mind! 10V loss Which wiring diagram are you looking at? Can you post the exact link? Tell me where your black and red meter leads are being placed.
Nate Gone Wild Join Date: Dec 2006 Posts: 679

07-09-2009, 04:25 AM	#9
khoff99 Not Yet Wild Join Date: May 2009 Posts: 54	Re: Complete overhaul loosing my mind! 10V loss Ok guys, I have some new data! I tried again last night looking at the DC amp draw and Voltage. I have 38V in forward coming from S1 and A1 at the motor. When I put it in reverse and back up the hill, the meter starts out at 100+ volts and then drops to 42. I'm not sure if it has something to do w/the polarity when switched to reverse. I know it's physically impossible to have 100V but I just don't understand it? I have an autocad drawing that i've created for just this reason. I can e-mail a word file however it's kinda hard to read.
khoff99 Not Yet Wild Join Date: May 2009 Posts: 54

07-09-2009, 07:22 AM	#10
scottyb Happy Carting Join Date: Dec 2007 Location: Southern California Posts: 73,410	Re: Complete overhaul loosing my mind! 10V loss Does the cart run okay? Did you check your meter and replace the battery?

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