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Electric Yamaha Electric Yamaha Golf Cars; G1 through "The Drive" and U-Max Utility Vehicles



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Old 08-10-2016, 07:06 PM   #1
Vabeachg19e
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Default 2001 G19e fails to move

3 weeks ago the cart had some issues trying to move, once it got going it cut off a couple times but worked fine for the rest of the weekend. I put the cart away for a week and now it does not move at all. I have been researching online for the past week and have learned a lot about these carts and some basic testing protocol. First things first the solenoid is not "clicking" so I cleaned all cables and posts and charged the batteries up fully. I tested the volts on each individual battery all 8.2v average I then tested the whole group and have 49.2 v. At this point I tested the solenoid with the negative end of the group and positive end to the small posts.....the solenoid clicked and continuity was good between bigger post so I put it all back together. I tested the key switch and it's good 49v on both sides....I tested the F/R switch and it tested 49v on forward and reverse side...I tested the start/stop switch and it's getting 49v on both sides and continuity checked out good.....tow switch checks out 49v on both sides when turned on and one side when turned to tow mode/off......did some checking on the controller plug also. I manually jumped the RED/BLACK and the solenoid engaged.....the 11 pin is at 49v and pin 3 shows 49v when pedal is depressed..and I did a few other checks. The buzzer has been deleted from this cart so no buzzer noise. One thing I did today I turned the cart on and jumped the 2 large posts on the solenoid and the cart moved!!!!! Besides testing the controller I'm at my wits end on this cart. I'm begging to think the controller is not working. Thank you in advance for all help given
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Old 08-10-2016, 07:20 PM   #2
Vabeachg19e
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Default Re: 2001 G19e fails to move

How about the throttle sensor? I have not tested that yet
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Old 08-10-2016, 07:25 PM   #3
cgtech
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Default Re: 2001 G19e fails to move

make sure tach sensor on end of motor is plugged in. plug reverse buzzer back in during testing. tow/run switch in run, key off. push cart around (by hand, not with another vehicle) and see if it beeps & resists your pushing. if it does not, sounds like the logic board in the controller is bad...
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Old 08-10-2016, 07:54 PM   #4
Vabeachg19e
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Default Re: 2001 G19e fails to move

PO removed and disposed of buzzer so I will not have one on hand...is it needed for this test?
And if it is the controller what should be my next step? Buy new?have it rebuilt? Or upgrade to a better controller?
Once again thank you for the help and quick response.
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Old 08-10-2016, 09:10 PM   #5
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Default Re: 2001 G19e fails to move

not really necessary for the test, but it should resist your pushing and beep at you until you stop pushing it. the beeping is just another confirmation. this test is "roll-away protection test" (so if you just hop off without setting brake, it wont roll freely down a slope). this test, if passed, would verify a good controller and a functional tach sensor circuit.
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Old 08-11-2016, 07:04 PM   #6
Vabeachg19e
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Default Re: 2001 G19e fails to move

So I did the test tonight. With tow switch on and off the cart can be pushed freely. I put a jump wire on the large posts on the solenoid and it drove all over the yard with no problem. Couldn't find a tach switch on the motor. The seems to be a 3 pin female coupling coming out of the harness from the battery section that's not hooked up to anything.The motor also has a blue case around it telling me maybe it's been replaced at some point?
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Old 08-11-2016, 07:12 PM   #7
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Default Re: 2001 G19e fails to move

so you did find the 3 wire plug to the end of the motor, and it was hooked up (but cart still failed "push test")? if you clip your meter wires on the solenoid small terminals (one on each side), do you get any reading when pedal pressed?
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Old 08-11-2016, 08:58 PM   #8
Vabeachg19e
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Default Re: 2001 G19e fails to move

The 3 pin female plug was not plugged into anything. There was not a plug on the motor for it to plug into. I will do the solenoid check tomorrow to see if it checks out with pedal depressed.
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Old 08-11-2016, 09:03 PM   #9
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Default Re: 2001 G19e fails to move

But I do remember there being 49v on both sides of the small posts even when cart was at rest or when pedal was not depressed. At the same time it showed 49v on both of the large posts a also. When tow switch was turned off I lost all volts on the controller side of the large post
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Old 08-11-2016, 09:35 PM   #10
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Default Re: 2001 G19e fails to move

49v on both small terminals just means B- was not being supplied at the time. solenoid B- is provided by the controller, it decides when the solenoid should be on.
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