G19E, no reverse (buzzer works) surging forward.

ardb

Yamaha G19E, serial tag---JR1 304010

Surging====
Batteries are 10 yrs old, so are scheduled to be replaced.
Low battery performance has generated the suggestion as the reason for surging. Voltage fluctuating between 50.8 to 47 while driving.
When holding brake and briefly pressing throttle voltage dropped to 46.
Would I be correct in thinking that new batteries will correct that problem?

No Reverse====
Forward/reverse switch seems OK.
Reverse buzzer sounds when moved to reverse position.
Full voltage through solenoid/relay in reverse and pedal when throttle pedal is
down.
Motor is getting full voltage through controller on red wire out to motor.

Any help will be appreciated.

Ard

BGW

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ardb

UPDATE TO ABOVE POST
This elderly friend has limited resources and batteries will be replaced as soon as possible. Trying to sort out other problems while waiting.

BATTERY PACK 49.9 VOLTS

RELAY 49.9 volts both sides of relay during all tests

CONTROLLER 49.1 VOLTS FROM RELAY
49.1 VOLTS OUT OPPOSITE SIDE ON LARGE RED.

Other threads suggested checking the following values
VOLTAGES AT MOTOR
FORWARD A1/A2 NO LOAD 0 V LOAD 6.2 V
F1/F2 NO LOAD 0 V LOAD 29.7V

REVERSE A1/A2 NO LOAD 0 V LOAD 0 V
F1/F2 NO LOAD 0 V LOAD -25 V
(APPEARS POLARITY REVERSED)

Surging===today voltage of pack at full throttle fluctuated from the 49.9volts down to 36.9 and back up.
One thread suggested such surging could be caused by poor batteries.

NO REVERSE===Voltage is passing thru reverse to controller as reverse buzzer is sounding. Notice no voltage in reverse with throttle down at A1/A2.
Does this indicate bad controller?

One thread suggested disconnecting plug at tach to see if reverse came back. This did not work.

Again any help would be greatly appreciated

ardb

addition to above

Roll-a-way braking does not work. I am assuming this cart is supposed to have this feature.

smallblock450sl

Time for new batteries.

kev2504

I agree. Install a new battery pack, and then see what problems you may have

Volt_Ampere

Surging is probably due to old battery pack with at least one sick battery. The pack voltage is probably sagging when you try to accelerate. Since they are that old, I would go ahead and have them replaced. Otherwise, you would have to load test them.

cartguy248

What did you find out with your cart? Did this fix the problem? I have one doing the exact same thing.

ardb

Have not replaced batteries yet. Old gent is trying to come up with the money.

I am pretty sure that is the problem with the surging. With Dig. volt meter on batteries and full throttle down the road, on last test,meter was bouncing from 49.9 down to 36.9.
I have been told these controllers don't like voltage below 48 volts. Its almost like the controller is turning on and off.
I am going to test again with dvm on controller side of contactor/relay to see if it is closing and opening.

Anyway batteries are to be replaced and probably a controller.

Volt_Ampere

I would replace batteries first. That may be the only problem!

cartguy248

All of my batteries load test fine and never drop below 7-7.5 volts. I have my cart jacked up in the rear and when its running at full throtle voltage jumps from 49-48v down to as low as 43.7. I will also try testing the sol. (contactor) for opening & closing.
Thanks