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Unread 08-01-2012, 09:05 PM   #1
Getting Wild
 
Join Date: Oct 2008
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Default 98 CC series cart won't go ....

Problem appeared out of the blue ... as they all do.
This is my last remaining cart. This one was giving me fits last year --- turned out to be several bad cells in the old batteries. I put all new US Batteries in it 2 months ago, it had been running fine. It gets very little (2-5 miles max per week) use and is plugged in nightly. Water level has been kept up. Batteries read 8.6/7 each and the pack reads 52.6

Went to pull it in for the night 2 nights ago and it wouldn't run at all. It has been out in several heavy T-storms recently.

So far i've checked the batteries and all wiring connections including the key switch, throttle pot and motor/controller connections. all are good.

Plugging it in to the charger does not kick the charger on, even momentarily.

I did the relay bypass on it just to check, the charger does hum indicating the juice is flowing, but the meter doesn't register anything at all.
No change after a 10 minute bypass charge session.

Reset the OBC. no change.

If i toggle the key switch a few times and hit the go pedal i sometimes get a very slight engagement, it is just enough to rock the cart forward but not actually move it.

the resistor that bridges the posts on the solenoid heats up if I hold the pedal down.

Should I try a straight jump across the two main solenoid terminal posts to test it? (on stands of course) Don't want to fry anything. Anything else i should look for?

If I can't get through this one easily enough, i may sell the batteries and charger off and use it for yet another offroad project

TIA
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Unread 08-01-2012, 09:19 PM   #2
Dawg Gone Wild
 
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Default Re: 98 CC series cart won't go ....

Clip a jumper wire to the small post of the solenoid with the yellow wire, NOT THE LARGE YELLOW WIRE... Clip the other end of it to the B- post of the controller and tell me what she does.
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Unread 08-02-2012, 08:17 PM   #3
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Default Re: 98 CC series cart won't go ....

Thank you.
The jumper brought it back to life--drives normally with it hooked up. (used 10g copper solid wire) At this stage I take it that the solenoid has had it?
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Unread 08-02-2012, 08:44 PM   #4
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Default Re: 98 CC series cart won't go ....

Quote:
Originally Posted by x-bird View Post
Thank you.
The jumper brought it back to life--drives normally with it hooked up. (used 10g copper solid wire) At this stage I take it that the solenoid has had it?
Nope, it tells you that the on-board computer has had it. Part number 101909901
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Unread 08-02-2012, 09:16 PM   #5
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Default Re: 98 CC series cart won't go ....

Quote:
Originally Posted by TahoeDawgZ71 View Post
Nope, it tells you that the on-board computer has had it. Part number 101909901
Gah! that's what i was afraid of. last year's "battle" with it seemed to indicate that, (charger hanging at 4-5 amps and drying out the batteries) but it also had bad batteries in it.
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Unread 08-03-2012, 08:07 AM   #6
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Default Re: 98 CC series cart won't go ....

Quote:
Originally Posted by TahoeDawgZ71 View Post
Nope, it tells you that the on-board computer has had it. Part number 101909901
have to 2nd that.........................................
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Unread 08-03-2012, 09:32 AM   #7
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Default Re: 98 CC series cart won't go ....

I think the Tstorms may have created a power surge which damaged your OBC.
Old batteries often make a charger run forever without shutting off.
A cart used very little does not need to be plugged in every night. You may be better off recharging only every 3 days or after each use. You can over charge the batteries.
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Unread 08-03-2012, 11:40 AM   #8
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Default Re: 98 CC series cart won't go ....

Quote:
Originally Posted by scottyb View Post
I think the Tstorms may have created a power surge which damaged your OBC.
Old batteries often make a charger run forever without shutting off.
A cart used very little does not need to be plugged in every night. You may be better off recharging only every 3 days or after each use. You can over charge the batteries.
For whatever reason, we have a lot of power spikes/brownouts in summer/loss of power in storms. Several years ago, after a particularly bad storm and loss of elect, I installed a 25K diesel genset that will run my entire house and shop.

A couple of years later I also installed a whole house power conditioner/surge protector. Before that I had burned out 2 chargers and a $800 A/C supply air motor and countless other sensitive elect conponets. Can't say enough about poor elect. power conditions distroying electric devices in the home.

BTW the divice I installed also saves me from 18-22% each month off my utility bill
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Unread 08-03-2012, 05:19 PM   #9
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Default Re: 98 CC series cart won't go ....

My place is the very last on PPL's line and i get the brunt of the brownouts etc. I run some pretty heavy service needs range lights, mini golf lights and big fountain pumps, ice cream shop etc. I've always getting low volt/amp readings in the summer when demand is high. the number of compressors and pumps I've gone through is nuts. Upped the service to a 750 amp transformer/feed a few years back and it has at least stopped my the buss bars on the back of my panels from burning up and melting. One quick power outtage takes out my lighting for about 20 minutes. last year a leg dropped off the transformer ... had me scratching my head as to why i had power except for my 240 (lights, pumps) until i spotted it hanging in mid air up[ on the pole. ...
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Unread 05-20-2013, 11:12 PM   #10
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Default Re: 98 CC series cart won't go ....

Finally an update on this old girl ...she won't let go!

Couldn't address the OBC problems in the wake of hurricane sandy, nearly wiped my place off the map. Have finally gotten the business back on it's feet and up and running and got back to this particular project.

Having checked around, i didn't want to risk a used OBC, so i opted for the lower-cost alternative to a new replacement. I could have just keep the solenoid jumped to the B- and charged on a self-timed basis, but I didn't want to risk frying the new batteries with an overcharge.
Installed this today ...

http://www.ebay.com/itm/280934982190...84.m1423.l2649

With a bad OBC it has you remove the yellow solenoid starter wire and route it to the B- (same basic jump as before), cut the negative feed from the recaptacle out of the OBC and put it to the B- then install the timer on the charger and eliminate the relay in the charger. Pretty simple install overall and it passed its first charge session and shut off correctly. Happy to have a running cart again. Probably going to have to put it up for sale though, been a rough start and anything that i can move to help defray soem of the expenses we just went through will be a big help.

Is 1,200-1,500 a reasonable range for a '98 DS (2 seat with bag holders config) with pretty much new US batteries and a bypassed/modded OBC/charger? (I'm basically clsoe to a grand into it again with the batteries and timer/controller) Body is in good condition, seat now has a little rip in one corner. tires are fine and plenty of spare tires and rims go with it.
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