Golf Cart Voltage Regulators (Installation & Testing) Everything To Know

 

There are two types of golf carts available in the market, gas-powered and electric.

In both these types and generally in all vehicles, it is important to ensure that the voltage generated is being evenly distributed throughout the cart.

The part responsible for this is the voltage regulator.

It is a simple device, but the functions it provides is directly responsible for the overall performance of the engine and the electrical components in the machine.

The voltage regulator helps limit and regulate the power being sent to the battery when it is charging, without which the battery will eventually die.

Most electrical carts use a 12-volt battery to power themselves.

The voltage should not cross 14.5 volts upon acceleration.

This is the ideal range at which the battery can be properly charged and is important for maintaining a long life for the battery.

The voltage regulator plays its part in ensuring that the volts never go beyond the 14.5 mark.

Anything above or below it will show that the voltage regulator is faulty.

Additionally, the voltage regulator will ensure that there is a steady flow of power, which also plays a major role in keeping the electrical functions of the cart running properly.

 

How Golf Cart Voltage Regulators Work

In order to achieve a steady, reliable voltage, the voltage regulator is the main device you need.

It generates a fixed output voltage, which remains unaffected by the input or load conditions.

The voltage regulator uses a simple design which uses feed forward and negative feedback control loops.

The voltage regulator also plays a major role in protecting electrical components inside the cart.

 

Types of Golf Cart Voltage Regulators

 

There are essentially two types of voltage regulators: linear voltage regulators and switching voltage regulators.

The more widely used voltage regulator is the linear one.

Its active pass element has a variable conductivity, which handles the regulation of the output voltage.

When a load is connected, the transistor is responsible for maintaining a constant voltage.

The difference between the output and input is leveled out by the transistor, and the excess is dissipated as heat.

For the transistor to vary the current flow, it must be in the Ohmic region or linear region.

The advantage of a linear voltage regulator is that it is fairly simple in design and uses very few components to perform its functions.

It is also robust in providing over-current and thermal protection.

It is easy to use and provides a wide array of functions at a low cost.

The switching voltage regulator is the second type of regulator in the market.

It is slightly different than the linear model in the sense that the transistor remains in either an off state or an on state.

By adjusting the on-time of the regulator, the constant output voltage is maintained.

Switching voltage regulators provide more efficiency that can go up to 95%.

Since it switches directly from on to off, the time it remains in the on state is very less, which saves a lot of energy.

The output voltage can be higher or lower than the input voltage.

 

How to Check If the Voltage Regulator Is Faulty

If the voltage regulator in the cart is faulty, you will see the following signs:

• Major electrical components such as the dashboard or lights will start fluctuating or dimming. This is a sign that the distribution of electricity is not even and is erratic. This is hazardous to the electrical components of the cart and can result in further damage by causing the components to catch fire or burst.
• The battery becomes drained, even though no electrical component was left on. This will mean that the voltage regulator is not sufficiently charging the batteries.
• The engine will start experiencing problems such as stalling or a lack of constant acceleration. This is due to the voltage regulator not being able to distribute the power flow evenly throughout the engine.
• The instrument cluster either stops working completely or malfunctions due to a faulty regulator.
• The readings on the voltmeter are erratic and unstable.

 

If you find the aforementioned issues in your golf cart, it is advisable to check the voltage regulator for any faults.

This is a fairly simple process and does not require a lot of time.

Remember, though, there will be variations in volt readings depending on the model of the cart and whether it is electric or gas.

 

Checking A Voltage Regulator

 

How to Test a Voltage Regulator in an Electric Cart

As mentioned above, the voltage regulator will show signs when it is not functioning properly and will essentially drain the battery and damage the electrical components of the cart.

 

To make sure this doesn’t happen, here is a guideline on how you can check the voltage regulator:

• Park the golf cart on an even, flat surface. Put the transmission in park mode and to be safe, place some stoppers in front of the wheels to keep the cart from rolling.
• Find the designated jacking point in the golf cart and use the proper jacking kit to lift the cart up. Ideally, the jack should be placed below the frame on the back of the golf cart.
• Lift the seats of the golf cart to find the batteries and keep a voltmeter handy.
• The voltmeter has 2 connectors, a red one and a black one. The red one has to be connected to the positive terminal of the battery, while the black one has to be connected to the negative terminal.
• Turn the voltmeter on and set it to 20 volts.
• Without pressing the forward pedal, if the voltmeter reading is 12 volts, this means that the battery is in good condition.
• Next, test the voltage upon acceleration. In this case, keep the voltmeter connected and press the forward pedal. This is the state at which the engine is running and the cart is generating power. Ideally, the voltmeter should show a reading between 14 and 16 volts, which would mean there is no issue with the battery or voltage regulator. If the reading is still steady at 12 volts, that means the regulator is faulty and is not functioning properly.

 

How to Test the Voltage Regulator in a Gas Cart

 

Although the process remains more or less the same, there are a few differences you need to know about when testing the regulator in a gas cart:

• Connect the voltmeter to the battery as specified above and keep the engine running.
• It is advisable to put the cart in a neutral position with the handbrake on. Don’t forget to place stoppers in front of the wheels to be on the safe side.
• After connecting the voltmeter, check the readings. The reading should be between 14 and 16 volts. If it is below the 14-volt mark, stop the cart and remove the wire above the starter generator.
• Connect a jumper to the stud of the starter generator and check the reading again. If the reading shows 15 VDC or more, the voltage regulator is faulty.

 

How to Test the Regulator on a Yamaha Gas Golf Cart

 

• Again, follow the aforementioned instructions to ensure that the vehicle is in a safe position and the engine is turned on.
• Connect the voltmeter to the battery terminals and get the reading. If the volt reading is above 15, it is a clear sign that the battery is being overcharged. This will essentially damage the overall health and life of the battery, so you need to get this fixed as soon as possible.
• Now, you need to check the reading after releasing the accelerator pedal. The voltmeter should show a reading of 12.5 volts or just around this value. If this doesn’t happen, this means the voltage regulator is faulty.
• However, if the voltmeter showed a reading less than 13.5 volts before releasing the accelerator pedal, try to earth the wire. Do this by grounding the yellow wire on the starter generator to the chassis.
• If the reading jumps to 17 or 18 volts, it is also a sign that the voltage regulator is faulty and needs to be replaced.

 

Locations of the Golf Cart Voltage Regulator

 

If you are experiencing issues with the voltage regulator, it is highly advisable to replace it to prevent further damage to the battery and the cart.

To do so, you need to know where it is located.

Generally, the voltage regulator is found underneath the seats and next to the battery.

In an EZGO cart, the voltage regulator can be found in the same place but in a black plastic shield.

The shield is shaped as a pyramid and has three wires of different colors.

The colors are red, green and black.

All serve a different purpose, so it is best to check which one goes where and does what before messing with it.

The green wire is connected to the starter generator on the front.

 

How to Install a Golf Cart Voltage Regulator

If it has become evident that the cart is showing symptoms of a faulty voltage regulator, it is time to change it.

The voltage regulator is a fairly simple tool to find, remove and replace.

However, since it is a highly important part for the overall performance of the golf cart, it is advised to follow the step-by-step directions mentioned below.

For your safety, it is recommended to be properly geared for performing such a task.

Wear gloves and safety glasses to ensure that your eyes and hands are covered and away from danger.

There are certain tools as well which will be required to replace the voltage regulator.

A wrench along with an appropriate tool to remove the voltage regulator as per the model will be needed.

 

Once you are prepared with the correct tools and safety equipment, follow these steps:

• Firstly, locate the voltage regulator in your golf cart. It is usually found near the battery underneath the seat as mentioned above, but the location of the voltage regulator may change depending on the model.
• Once located, find the battery. The battery has to be completely disengaged in order to prevent a spark or any sort of mishap. In other words, no electrical flow must be going through the vehicle when working on it.
• Using a wrench, carefully loosen the battery terminals. It is important to remove the negative terminal first, which can be found by reading the sign on the battery.
• Once the negative terminal is removed, follow a similar procedure to remove the positive terminal, thereby completely disconnecting the battery.
• Once the battery is disconnected, it is safe to remove the voltage regulator. It can be removed either by using a special tool which would be mentioned in the user manual or by contacting an expert to know which tool will be used op open the regulator on your specific model. Usually, the voltage regulator is connected using latches and bolts.
• Safely remove the voltage regulator and get ready to place a new one.
• The new voltage regulator will have to be fitted using bolts and latches. It must be tightly and securely installed so that there is no malfunction.
• Once the new voltage regulator is installed, it is time to test whether it is running correctly. Use a voltmeter and connect it to the terminals of the battery. The reading should be 12.6 volts, provided that there is no spin.
• Then, press the acceleration pedal on the golf cart. This will generate some power. Ideally, the RPM should be 1,000. Once this happens, the voltmeter should be showing a reading of 13 volts with a 0.5 difference. If these readings are achieved, it means that the voltage regulator has been installed correctly.
• As a standard maintenance procedure, it is advisable at this point to check the fluid levels of the battery. A dry battery is as good as dead. Therefore, if the need arises, fill up the electrolyte levels using distilled water, ensuring that the levels reach the desired marks.

 

When installing the voltage regulator, ensure that the regulator is placed on a metal frame.

Using a plastic frame can potentially damage the regulator and the plastic itself because of the heat dissipation capacity of the regulator.

Using a metal frame will ensure that the electrical components function effectively and safely.

Maintain a distance of 2 inches on either side of the voltage regulator from any other mechanical or electrical component to avoid interaction or any sort of mishap.

It is also important to ensure that there are no mechanical or rotating parts in and around the voltage regulator.

This will keep a safe distance of the wires from other parts.

Using an 8 VDC battery will be ideal for the cart and regulator as they function best with these specifications.

Two 8V batteries will have to be installed as a standard.

 

Changing the Voltage Regulator Example

 

Common Issues Related to the Voltage Regulator and How to Fix Them

 

As easy as it sounds to install, the voltage regulator could be a problematic item as well.

In most cases, the voltage regulator will overheat, thereby affecting performance.

What are the possible reasons for the voltage regulator to overheat?

Improper pin connections in the voltage regulator are one of the most common reasons.

As a general rule, the positive ground regulators follow the input, ground and output formula, while the negative follows a ground, input and output series.

If the regulator does not have a bypass capacitor, which is responsible for ensuring that smooth current flows through it, the regulator may overheat.

Another common reason is the extreme tightening of the starter engine belt.

If the belt is very tightly connected and does not have any deflection, the regulator may overheat as well.

Although there are different fixes for different issues, generally when it comes to fixing a voltage regulator, the following steps are the standard solution and may be considered:

• First, try removing the grounding of the green wire from the regulator to the starter generator. The grounding is responsible for creating a maximum of 18 volts of charge, which is bad for the regulator and even the battery.
• You can also try removing the grounding of the yellow wire, which is connected to the starter and is responsible for the maximum current flow. This effectively damages the battery and the voltage regulator simultaneously.

 

Conclusion

 

This article highlights the key features and benefits that a properly working voltage regulator brings to the table.

It is not hard to understand that an even and undisrupted voltage flow throughout any machine is important.

On the other hand, an uneven, distorted and erratic flow of voltage not only damages the electrical components in a machine but also harms the overall health of the engine.

If the engine is forced to run on a low voltage, it can never achieve its desired performance levels and internally damages the engine too.

The voltage regulator also plays a crucial role in maintaining the life and health of the battery.

If it is faulty, it will directly affect the battery since the latter will not charge as the engine runs.

This puts all the load on the battery and damages it by reducing its lifespan.

It will also drain the battery quickly and require it to be recharged more frequently.

Therefore, purchasing and installing a proper voltage regulator is crucial for the health of your golf cart.

The issues that a normal golf cart faces are mostly related to erratic voltage flow, so the right regulator will get rid of most problems.

It will do a fine job of maintaining a smooth and safe ride.

A couple of great brands to consider for a voltage regulator is Bosch and Hitachi, which make reliable and high-quality products.

Of course, they are compatible with different golf cart models too, so you are bound to find one for your cart.

It is always recommended to purchase important electrical components, such as voltage regulators, from reliable companies that are known to manufacture parts that do not cause issues.

If a component such as this functions incorrectly, it directly affects other major parts of the engine and instrument panels of the cart.

You can ensure that a bigger loss is avoided by regularly checking the voltage regulator.

It is also a good idea to replace the voltage regulator frequently because, as mentioned above, it dissipates excess heat and has a relatively short life.

Although the process to install and test the voltage regulator is a simple one, it is always advisable to approach a professional who understands the intricate details.

They will make sure it does not get faulty anytime soon and keeps functioning properly and smoothly.