CarryAll Problems

dogdad11

Greetings -

I work for a State Park and we were given the '05 CarryAll ll in DOA condition. I've found lots of posts on the other models but almost nothing for the CarryAll. Is the CarryAll 2 the same (electrically and/or mechanically) as a Precedent or a DS, or is it a different animal altogether?

When it came to me, the batteries were completely flat so I pulled them out and jumped a set of fully-charged 12v batteries from one of our older ClubCars just to try and get it going. Nothing except...
• The battery-indicator only shows one bar, even tho I measured the temporary batteries as good (ie 48v).
• Reverse buzzer does come on when switch is in Reverse, but that’s it.
• The solenoid gives a very light click, but only when the pedal is about ½ -way depressed (The solenoids on our other Cars are a lot more noticeable when they energize).
• Car doesn’t move, but will give a slight ‘twitch’ when depressing the pedal after switching from R to F.
• As a sidenote, it looks like somewhere in its past, someone had installed a solar panel on the roof. It seems to be a good installation, but there a few extra wires/etc I have to contend with. For instance, there’s a small relay behind the dash that is wired in with the key-switch somehow – haven’t figured that out yet.

I’ve studied a lot of the wiring diagrams in the ‘Sticky’ section, but since they don’t specifically reference the CarryAll’s, I’m not sure which to follow. The closest I can find seems to be the one called “03cc48Vwiring”.

Sure would appreciate it if anyone could help me get started with explaining the differences between the cars, and maybe even have an idea as to what may be wrong.

Many thanks!

BGW

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mrgolf

That relay in the dash is likely to power a 48 to 12 volt reducer. Look for wires from it see were they go. They will not be in a wiring digram. I don't think jumping will give you enough amps to tell a whole lot. Put a set of batteries in it, charge up good. They should read 51 volts full charge. Then see what you have. The relay could have something to do with the solar panel also.

dogdad11

Thanks for the info about that relay. I kinda suspected it might have been for something besides the basic cart, as it was Y'ed into the cart wiring whereas the rest of the wiring was direct. I also found a small box that said "ZFK-36 Intelligent Solar Controller" near the batteries that had the same kind of Y-connections interfacing it to the cart. Couldn't 'google' up anything on the box, tho, so I dunno anything about it.

I shoulda been more clear on my explanation about 'jumpering', sorry about that. I'd removed the 8v batteries, and temporarily set my 12volt ones on the cart-floor, then wired them together with the 6-ga cables (since they wouldn't fit under the seat). Obviously not safe for a run down the road, but I'm just hoping to get it to move right now.

Which wiring diagram (DS, Precedent, other?) should I be following to get to the basics of what's supposed to go where so I can start troubleshooting point-to-point? I'd like to remove all of the add-on wiring for that relay and solar box, but reluctant to just start pulling things off.

Thanks!

mrgolf

CTD is the wiring guru. We have several on here that have carry alls. I'm sure they will chime in soone. As for the add on wiring, if you can find both ends you will know what it is for I think. I'm one of those people that learn from doing. Just don't do anything you can't undo.

Epb

Post the serial numbers you can find and a picture of the battery area and controller. Ctd crash test dummy will hook you up but i usually see him ask for such to get a head start.

Epb

Look here this might help find the numbers
http://www.buggiesgonewild.com/elect...locations.html

dogdad11

Had to run back to work to get the serial number... E0547-572642.

That says it's a fairly-late 2005 CarryAll II, but what's it closest-to wiring-wise?

Epb

https://www.google.com/search?ie=UTF...b+car+carryall

I dont know if this link comes thru but it went to first search of mobilcab.com/pdf/2004-2005-turf-caryall.pdf and it downloaded 476pgs of manual and the wiring diagram is there it will not allow me to attach

Check it out

dogdad11

Wow, thanks Epb!
With all the googling I've done to find out anything about the cart, I never ran across that link. Now I know why I had to get the kid down the street to set up my new phone for me, I guess I'm still in the 20th century.

Looks like it's back to work for me now...

Stevegrmich

. . if after charging you only have 48v on those batteries, they are bad . . . 48v only represents about 40% of full charge . . .