Help! 1999 48v DS Wiring ? New To Me

[gn386]

So I just traded my big block CC (in My Sig) conversion for this one. I have what I believe is a Powerdrive Plus Regen 2 variety. (please correct me if I am wrong)What I noticed is that it goes well on flat ground but hills are a killer for it. Batteries are 6-Crown 185's no OBC. Prev owner stated that the controller (silver) had been replaced (not too sure about that) has worn sticker on front. Needless to say it charges well and goes pretty good. It was pretty dead when I got it but took 16 or so hours maybe to reach a full charge. I can never leave things alone so I was going to put some high quality 2ga welding wires through it to help with current flow. While I was looking to identify what version I have, I noticed that the left side solenoid with the resistor has the brown and orange/white stripe connected. The #white from it is just disconnected on the motor side and the #6 white from the motor is connected directly to the controller. All I have found is showing that the solenoid should be between. What would be the reason that they disconnected? Is this the reason that it has issues? Do I need to get to testing to see if it's good or leave as is.

[gn386]

Oh I should also say it has 14" wheels and 23" tires as well currently

[Fairtax4me]

It’s just gonna be slow on 23” tires. Those old regen Sepex motors are way low on the torque output and have a hard enough time climbing hills on stock 18” tires. 23”s nearly cut your torque delivery to the ground by half.

The solenoid with the resistor is the dynamic braking solenoid and it’s common to bypass that if the resistor or the solenoid fails. It disables the dynamic braking, but retains the downhill over speed control which will try to flip you through the windshield if you reach too high speed going down hill or take your foot off the pedal.

Either way, it’s gonna be slow. A complete drive system upgrade, motor, controller, wire harness, throttle system, would be necessary to continue running those larger tires and expect to go up a hill at any normal speed.

[gn386]

Can’t believe the only solution is to basically redo the entire cart at once. There has to be some stages that can be done? Maybe I am looking at this all wrong....

[Fairtax4me]

Yeah the problem is Amps = Torque. And You need Torque to turn big tires.
You can make some incremental upgrades. Alltrax does make an XCT controller that will plug into the Regen2 harness.
The reason I say to upgrade the wire harness to an IQ harness is there are some issues with the Regen2 harnesses that can cause problems. It’s also more complicated to upgrade the throttle control. The pie-wedge V-glide throttle will work, but it’s a multi-step pot and you will always have some jerkiness in the throttle response because of that. Some can be tweaked out with settings in the alltrax, but it will ever be as smooth as the MCOR continuously variable pot throttle used by the IQ system.

An Alltrax controller upgrade will give you some extra power going up hills and open up the speed a bit.
The stock motor is still very limited power wise, and is not going to be happy for long trying to push those big tires around. You can get by with it for a while by tuning down the output of the XCT controller, but the stock motor can only do so much.
One other option would be to step down in tire size. A 20” tire will make a noticeable difference in climbing power. You’ll lose a few mph on the top speed, but if there are a lot of hills in your area it will be much better off to be able to climb.

Something else to consider is the shape the batteries are in. How old are they? How much does their voltage drop when under load? An older battery pack that’s lost some of its capacity will have a higher voltage loss when put under load, and that means decreased power.

I’m far from an expert on these sort of upgrades, but if you want to be able to turn 23” tires on hilly terrain, you’ll never be happy until the entire drive system is upgraded.
For better advice on what you can do now, and what you can do to plan for future upgrades, Get in touch with ScottyB at CartsUnlimited.
Or David at Revolution Golf Cars.
Both of those guys are experts and will know the best approach to get you the performance you want.

[gn386]

So today was the day I decided to put the cables on. It was fairly cut and dry and went well until one stud on the motor sheared off. They were all pretty **** corroded but that last one just rung off. Now I am close to doing the motor, controller and solenoid. Can't see throwing away money on the stock one.