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Unread 04-05-2016, 09:06 PM   #1
Not Yet Wild
 
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Default 2010 Carryall 252 stalls immediately

I am a long time reader and first time poster. This is a fantastic forum. I purchased a 2010 Carryall 252 and recently installed new batteries. The cart has begun to stall immediately after I press the accelerator pedal. Upon pressing the pedal, I hear the solenoid click and the cart moves about 5 feet and then I hear a second click causing the cart to suddenly stop. These are the things I have tried so far:

Tested battery voltage: 48 volts
Tested each battery without disconnecting them: 7, 7, 7, 7, 7, 7, 7, 4 volts
MCOR bypass with paperclip: no effect
Reset OBC: no effect

I monitored the voltage during the acceleration and the voltage dropped to ~30 volts just before the second solenoid click. This happens when I fully press the pedal. If I slowly press the pedal I can get the cart to move slowly without cutting out.

Thanks in advance for any ideas.
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Unread 04-05-2016, 11:17 PM   #2
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Default Re: 2010 Carryall 252 stalls immediately

Is this with eight 6-volt batteries or something else? Either way you see that 4 volt battery? No matter if a 6 volt or 8 volt it is BAD... Or installed backwards! See where your dropping down to 30 volts? Even on a 36 volt cart that is bad on a 48 volt cart that is REALLY BAD....
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Unread 04-05-2016, 11:39 PM   #3
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Default Re: 2010 Carryall 252 stalls immediately

Definitely a low voltage/battery issue
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Unread 04-06-2016, 12:11 AM   #4
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Default Re: 2010 Carryall 252 stalls immediately

Thanks for the feedback. This cart has 8, 6-volt batteries. I've been searching the forum for related issues and I saw post by Sergio who said, "A common mistake is to accidentally run the positive wire from the charger receptacle to the wrong battery. If that wire is not connected to the pack positive, You will not charge the first battery and it could fail under heavy current demand." I checked the cart tonight and the red wire from the charger was connected to the positive terminal of the 7th battery, not the 8th. I fixed this and I'm charging tonight. Hopefully this fixes the problem. BTW, the batteries were installed by a local golf course mechanic a few weeks ago.

Thanks again. I'll update tomorrow.
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Unread 04-06-2016, 06:07 AM   #5
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Default Re: 2010 Carryall 252 stalls immediately

Sounds great... Love it when the fix is to correct a simple mistake...
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Unread 04-06-2016, 06:26 AM   #6
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Default Re: 2010 Carryall 252 stalls immediately

Hopefully a few weeks did not kill the battery, but that voltage is pretty low.

The voltages also don't add up, follow the cables to make sure they all go from positive of one battery to negative on the next and no battery is wired backwards.

Set your meter to 20vDC when measuring a single battery so You get 2 decimal places of resolution on the meter.

Set the meter to 200vDC when measuring the entire pack, compare the measurements to make sure the batteries add up to the pack voltage.
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Unread 04-06-2016, 06:39 AM   #7
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Default Re: 2010 Carryall 252 stalls immediately

Quote:
Originally Posted by Sergio View Post
Hopefully a few weeks did not kill the battery, but that voltage is pretty low.

The voltages also don't add up, follow the cables to make sure they all go from positive of one battery to negative on the next and no battery is wired backwards.

Set your meter to 20vDC when measuring a single battery so You get 2 decimal places of resolution on the meter.

Set the meter to 200vDC when measuring the entire pack, compare the measurements to make sure the batteries add up to the pack voltage.
Sergio sees all knows all... Yes something is still not right as 6 volt batteries should read 6.4 volts with a full charge not 7 volts; unless the reading was taken during the charge cycle or too soon thereafter?
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Unread 04-06-2016, 09:52 AM   #8
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Default Re: 2010 Carryall 252 stalls immediately

I charged overnight with the new connection but the cart still stalls immediately. 6 out 7 batteries read between 6.35 and 6.40 volts and the last battery reads 4.47 volts. This should give a total battery voltage of ~49 volts but the pack measured 52.4 volts. Any ideas? Is one bad battery enough to prevent the cart from moving? Thanks again for your input.
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Unread 04-06-2016, 09:58 AM   #9
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Default Re: 2010 Carryall 252 stalls immediately

That low battery is preventing the cart from pulling enough current to run. You need to replace it. You could try charging it separately and see if it takes a charge but it was probably actually reverse charged by the pack when it ran down to zero.
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Unread 04-06-2016, 10:33 AM   #10
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Default Re: 2010 Carryall 252 stalls immediately

If you put a voltmeter across the pack, hold the brake and push the gas slowly you will be surprised at what the voltage drops down to. I have seen carts at 50V sitting but as soon as you press the gas or put a load on the pack it drops right down to 20-30V and shuts off. When batteries get that bad there is no solution but to replace them.
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