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Old 03-01-2014, 11:43 AM   #1
Pixguy
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Default 98 Electric txt issues

Well, after replacing the batteries, body and a few support bars, our "new" cart was running good.
Then my 84 year old stepfather tried to move it up a hill and it died on him.

I am not a mechanic and know just some about voltage testing but the batteries appear to be fine with the meter reading 38+V. We do get a click from the solenoid when depressing the gas pedal. I tested the voltage to the motor and it read 23+V when the positive was on the red wire and the black on the battery neg.

Any advise?

Thanks in advance.
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Old 03-01-2014, 12:26 PM   #2
JohnnieB
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Default Re: 98 Electric txt issues

Have to know which drive system to troubleshoot it.

When was the last time the batteries were charged? (New batteries should be charged after installation and before the first use, then charged after each subsequent use.)

The solenoid is clicking, so the problem is in the high current circuit.
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Old 03-01-2014, 03:20 PM   #3
Pixguy
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Default Re: 98 Electric txt issues

Quote:
Originally Posted by JohnnieB View Post
Have to know which drive system to troubleshoot it.

When was the last time the batteries were charged? (New batteries should be charged after installation and before the first use, then charged after each subsequent use.)

The solenoid is clicking, so the problem is in the high current circuit.
Thank you Johnnie, without taking the motor apart, it looks like I have the series type because that's what my equipment looks like.

The batteries are new and we have plugged them into the charger we got with the cart, assuming the charger is good, which I gather is because I got a voltage reading of 38v at the batteries.
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Old 03-01-2014, 04:58 PM   #4
JohnnieB
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Default Re: 98 Electric txt issues

A 36V battery pack should read about 45V when the charger shuts off and 38.2V about 12 hours after the charger shuts off.

If there isn't a Run/Row switch om the controller cover, it is a series drive.

Hers is a schematic for a series drive with the high current circuit highlighted. (If the solenoid clicks, the problem in in the high current circuit)

Quote:
I tested the voltage to the motor and it read 23+V when the positive was on the red wire and the black on the battery neg.
Where exactly did you read 23V?

Since the cart stopped suddenly, it also might start suddenly, so jack the rear wheels off the ground so the half ton cart doesn't run over somebody or something.

Connect your negative voltmeter lead to the main negative post on the battery pack and the positive voltmeter lead to the M- terminal on the controller.

Push pedal just far enough for solenoid to click.
You should read FULL battery pack voltage.

If you get full pack voltage, push pedal to floor and the voltage should decrease to Zero, or very near it.


If you don't get full pack voltage, start measuring various point closer to the main positive terminal on the battery pack until you find it.
Attached Images
File Type: jpg Wiring Diagram - Series- Hi-Current traced.JPG (59.3 KB, 0 views)

Last edited by JohnnieB; 03-01-2014 at 05:56 PM.. Reason: Forgot the attachment
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Old 03-01-2014, 06:34 PM   #5
Pixguy
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Default Re: 98 Electric txt issues

Quote:
Originally Posted by JohnnieB View Post
A 36V battery pack should read about 45V when the charger shuts off and 38.2V about 12 hours after the charger shuts off.

If there isn't a Run/Row switch om the controller cover, it is a series drive.

Hers is a schematic for a series drive with the high current circuit highlighted. (If the solenoid clicks, the problem in in the high current circuit)

Where exactly did you read 23V?

Since the cart stopped suddenly, it also might start suddenly, so jack the rear wheels off the ground so the half ton cart doesn't run over somebody or something.

Connect your negative voltmeter lead to the main negative post on the battery pack and the positive voltmeter lead to the M- terminal on the controller.

Push pedal just far enough for solenoid to click.
You should read FULL battery pack voltage.

If you get full pack voltage, push pedal to floor and the voltage should decrease to Zero, or very near it.


If you don't get full pack voltage, start measuring various point closer to the main positive terminal on the battery pack until you find it.
1. I don't know what a run/row switch is.
2. Is the full battery pack 38v? 12 hours after charging?
3. I take it the controller is the black box behind the solenoid. Is the M terminal obvious or is there something that should make it stand out?

Thanx again John for your patience.
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Old 03-01-2014, 06:45 PM   #6
vagabond
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Default Re: 98 Electric txt issues

I think Johnnie has fingers like mine and sometimes hit the wrong key, it should be run/tow switch
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Old 03-01-2014, 06:59 PM   #7
Pixguy
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Default Re: 98 Electric txt issues

Quote:
Originally Posted by vagabond View Post
I think Johnnie has fingers like mine and sometimes hit the wrong key, it should be run/tow shitch
haha I first thought.... ruhroh

Tanx Vag
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Old 03-01-2014, 08:36 PM   #8
kellybell
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Default Re: 98 Electric txt issues

Row is when you accidentally drive your cart into a water hazard....row........
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Old 03-02-2014, 07:53 AM   #9
JohnnieB
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Default Re: 98 Electric txt issues

Quote:
Originally Posted by Pixguy View Post
1. I don't know what a run/row switch is.
2. Is the full battery pack 38v? 12 hours after charging?
3. I take it the controller is the black box behind the solenoid. Is the M terminal obvious or is there something that should make it stand out?

Thanx again John for your patience.
1. Run/Tow - I fumbled fingered it. Switch is on the controller cover as shown in the attachment I posted.

2. Full battery pack voltage is whatever the battery pack voltage is at the time. If the pack measures 39.7V, then you should measure 39.7V at M- when the solenoid contacts close.

Batteries acquire what is known as a surface charge during the last part of the charging process. A 36V charger typically takes a 36VV battery pack up to about 45V before is shuts off and it takes about 12 hours for the surface charge to bleed off.

The significance of this is that the surface charge isn't accurate for estimating the batteries SoC (State of Charge) from the voltage.
Attached is a Voltage vs SoC chart.

3. the M- terminal is one of the three or four large terminals on top of the controller, which is the black box behind the solenoid, and all should be marked with raised letters next to them.
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File Type: jpg JohnnieB's SoC Chart.JPG (63.9 KB, 0 views)
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Old 03-02-2014, 08:33 AM   #10
Pixguy
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Default Re: 98 Electric txt issues

Ok, with the positive on the M, I get a reading of 36.3v and when I press on the pedal and hear the solenoid click, the reading goes up to 38.5v.
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