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Unread 01-03-2010, 10:20 AM   #1
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Default DS Series 1995-96 Power Failure

Hi,
Power failure started as intermittent accompanied by occasional flickering batt light. Solenoid or solenoids can be heard operating when the go pedal is depressed and there is sometimes faint one or two shudders as when batteries are very low. After towing for three fairways it came good , with good power considering the old batteries. All contacts were either renewed or cleaned and batteries checked ( no hydrometer just electrolyte levels) and recharged overnight and the cart operated normally for 90 minutes or so the following day with plenty of stops. Back on Charger for overnight, then next day a couple of 100 yard runs or so OK , then quit again altogether, back to a click or two from a solenoid and a meek shudder but no go , either forward or reverse. I'm OK on principles but my knowledge of the detail of these things is very limited. I suspect a problem with either whatever controls the varied power input to the motor solenoid(s), brushes contact on the motor armature ( these have never been serviced to my knowledge), or maybe the batteries have finally crumped . I have read several posts on similar problems mostly with different models but I don't understand all the terms and abbreviations used .

Some tech advice on how to sort this out ASAP would be much appreciated so that I can get my aged body back on the course before I forget how it's meant to be done ! Many cheers!
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Unread 01-03-2010, 10:25 AM   #2
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Default Re: DS Series 1995-96 Power Failure

Sounds like we need to start with the basic battery evaluation. Specific gravity readings done at least 1 hour after recharging would ve good. Along with digital voltmeter reading taken at the same time..... Post them like this if you can.
This will give us the best analysis short of a load test.

Battery #1 = 8.12 volts 1.15 SG (specific gravity)
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Unread 01-03-2010, 10:43 AM   #3
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Default Re: DS Series 1995-96 Power Failure

OK , Thanks scottyg for your prompt reply. If my hydrometer reads in figures expect the info in 24 hours. The best!
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Unread 01-03-2010, 10:54 AM   #4
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Default Re: DS Series 1995-96 Power Failure

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Unread 01-03-2010, 05:52 PM   #5
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Smile Re: DS Series 1995-96 Power Failure

Meanwhile scottyb (not g, sorry) , on sourcing batteries in Aust , if Trojans prove difficult , an alternative offered is another American battery
Model No US8VGC
260L x 181W x 283H (these will be millimeters)
170Ah
Comment: Set of 6 seem bit expensive but we gotta pay stupid CO2 tax!
Without getting a tape out , and off the top of your head do you have a yes , or a no? Amp hours , known life histories, terminal sizes , OK?

Cheers,
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Unread 01-03-2010, 09:12 PM   #6
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Default Re: DS Series 1995-96 Power Failure

They twist and convolute the test results so that each appear to have the best battery for the $ Truth is that the amps you want are stored in the lead plates and these plates make up 99% of the battery weight.... The more lead plates the more amp storage capacity = the better performance..... So judge batteries by weight. Get the heaviest battery you can and break it in properly! You won't go wrong.
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Unread 01-04-2010, 03:02 AM   #7
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Exclamation Re: DS Series 1995-96 Power Failure

Hello again scottyb,

Your comment on batteries is understood . Test results today follow: First I question reliability of my cheap-charlie multimeter . Voltage readings initially were all somewhat erratic and very low around 6.7 to 7 volts, finally got some good readings , ie, steady and more reliable I think,

Test 1. Charger ON for 24 hours , then OFF for 2 1/2 hrs before tests.

Batt#1 8.1 v Cells SG 1.170, 1.200, 1.200, 1.200

Batt#2 8.4v Cells SG 1.275, 1.280, 1.230, 1.275

Batt#3 8.2v Cells SG 1,230, 1.170,1.230, 1.230

Batt#4 8.4v Cells SG 1.275, 1.275, 1.262, 1.250

BATT#5 8.3V Cells SG 1.1.227, 1.260, 1.200, 1.200

Batt#6 8.3v Cells SG 1.200, 1.200, 1.225, 1,255

Over-all 49.2v

Test 2. After 7 hours off the charger

Lower Batt volts all 7.6 to 7.9v Cells SGs much the same, maybe a bit lower but Cell 2 in Batt #3 gave a lower reading, and over-all reading was 46.9v . I doubt the multimeter for some of these. It quit reading at all at one point despite a new battery fitted between tests.

Batts might be close to death but still kicking?

New fault:- Notably, and this has never happened before in my history with this cart, the charger would not click on and start to indicate after plug-in following either of my tests. I have left it connected but doing nothing. During the tests the Batt low warning light would come and go intermittently. Go pedal still producing one clear solenoid click, little else .

I slammed the FWD/REV lever to and fro a few times , that seemed to produce a bit more than just the solenoid click, cart even started forward an inch or two once!

Is there a built-in device which controls the battery charger? I checked out my charger on my neigbour's identical cart . all OK, and got same -ve result on my cart with his identical charger.

Such is 'trickery! I have a tech man coming Wednesday morning , but any further input you can spare would be very welcome.

I am most grateful for your help

Cheers
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Unread 01-04-2010, 09:29 AM   #8
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Default Re: DS Series 1995-96 Power Failure

Well Done Peter
I wish everybody would do so well. There is clear evedence that the batteries are indeed dying. The low S/G readings and falling Voltage tell the tale. THere is a built in on board computer (obc) to control the charger in this model. You will see one of the battery cables is routed through it, so that it can take readings. Change out your batteries and put new cables on them. Clean up the charge wire connectors to the batteries and then see how your charger works.
Battery break-in, maintenance, & use proceedures are more of a determining factor in battery useful life than Brand..... Remember to choose the batteries by weight

Here is some good reading on battery break-in proceedures. Charge BEFORE use. Good Luck

Battery breakin or break in procedure procedures


Print and keep this chart below for future reference. And never draw the pack down below the 50% level
Attached Images
File Type: jpg Batterytable1-1.jpg (88.7 KB, 50 views)
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Unread 01-05-2010, 03:36 AM   #9
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Default Re: DS Series 1995-96 Power Failure

It's the mouth from the south again. Now found Serial number A9805-645258 =February '98 DOB for this cart , still DS and Series I think.

Scottyb,
Following instructions from earlier posts of yours and the sticky, the OBC checked out not burnt, so then re-set for more than 5 mins with main -ve off Batt #6 disconnected , key SW ON, reverse selected and full bore on the go pedal . Lo n behold! After re-connection the charger now works, and after half an hour or so , Batt low light still coming ON, the wretched cart would now move back and forward, but seemed "jerky on the throttle" . Multimeter replaced with a new one , ready for new tests tomorrow by the tech man. If things go true to my experience , I expect he'll "ground test it , find it serviceable!" .

How can I check for the smooth functioning of the GO pedal rheostat or potentiometer please? From the quarter circle box it's in just alongside battery # 4, looks like it may be a wiping arm rheostat of some sort. Would not be easy to get to.
Cheers

And new set of new Trojan T875 are on standby.
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Unread 01-05-2010, 09:32 AM   #10
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Default Re: DS Series 1995-96 Power Failure

A 98 would have an MCOR throttle position indicator..... here are the test proceedures. I apologize for the crappy resolution. Cick on em to enlarge then click on em again, & maximize that image Good luck
Attached Images
File Type: jpg MCOR Test (1).jpg (85.7 KB, 9 views)
File Type: jpg MCOR Test (2).jpg (107.6 KB, 3 views)
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