2003 G22 worked spontaneously after removing/replacing fuse, now completely dead

kabinski

Initial problem: Cart would only move slightly at a snails pace when slowly pressing accelerator. When pressed too fast, or past a certain point, cart would stop running altogether. After checking a few things I learned to check from my troubleshooting searches, including cleaning corroded male/female ends of plug of speed/accelerator control (attached via rod to the accelerator pedal), bypassing the solenoid, checking cables/wires, etc., I found the problem to be a malfunctioning battery. I replaced the battery with another (used, but of a different brand) and that seemed to fix the problem. However, after driving the cart a couple of miles, it died. I simply removed and re-installed the fuse next to the solenoid, and the cart worked fine for a few more miles. It died again, and like last time, removing/re-installing the fuse worked again. Prior to this, the cart was hooked up to the charger and fully charged as usual. The batteries were all measuring about the same voltage, as well. The next time I drove it, it made it about a half-mile and completely died again. The fuse trick did not work this time (even after trying it a few times). There is no clicking noise from the solenoid now after turning the key and pressing the pedal. Completely dead.

Any tips on what it may be? Thanks.

BGW

__________________
This advertising will not be shown in this way to registered members.
Register your free account today and become a member on Buggies Gone Wild Golf Cart Forum

kabinski

I just tried to by-pass the speed controller that I read about somewhere on here. After that didn't work and I hooked everything back up, the cart was working normal again. I tested it for about a ten-minute ride and all was well. However, after parking it for a few minutes, and trying to go again, it didn't work. After pulling and re-installing the fuse, it worked OK for a few seconds, then briefly worked intermittently before dying again. At which time it would make the normal hum and solenoid clicking noise, but refused to budge. Yet once again, a pull of the fuse made it work, but even more briefly than the last time. Any help as to what to try next would be greatly appreciated. Thanks.

craig tn

What is the voltage of the battery pack and each battery? Does resetting the tow switch do anything?

kabinski

The voltage of the pack is 50.6. The voltage range for each battery is 8.41 to 8.48.

I just found this statement on-line from a google search... "For 48v carts if any battery reads below 9.3v and is not within 0.5v OF ANY OTHER BATTERY in the set. Replace that battery." Found it here... http://www.ehow.com/how_5504467_chec...batteries.html

Is this true? If so, sounds like I need all new batteries. BTW, they were manufactured in 2005. If it matters, the brand is US Battery "US 8V GC". The one replacement battery is a Trojan. It reads near the middle of the range of the other 5 batteries at 8.43v.

craig tn

Check the voltage while riding the cart. Does the tow/run switch do anything instead of pulling the fuse? Flip to tow weight a few minutes and flip to run and see if it will go. Also have to try to go slow after pulling the fuse, sometimes with low or bad batteries a yamaha will pull at a slow speed but shut down trying to go fast.

kabinski

Tried the tow switch again, but that didn't work. Pulled the fuse after that and still no luck. After sitting a few days not hooked up to the charger (and not able to run during that time), the voltage for each battery is currently around 8.31 to 8.33. I measured the voltages again after I hooked up the charger and each battery jumped up to 9.02 to 9.07 volts. Across the pack, once hooked up to the charger was 54.5v.


Update... At a little over 80% charge, the batteries are currently reading around 9.45v each. I just tried running it while hooked up to the charger. When pressing the pedal normal speed, nothing happened except the click from the solenoid. Forward nor reverse worked. Like you suggested, Craig, when I pressed very slowly it finally worked and the wheel seemed to be spinning full-speed once pressed all the way down. Reverse worked the same. After doing the slow pedal press method a couple times, I tried pressing it quickly once again and it was now working fine that way also.

Does it sound like it's time for new batteries? Thanks for your help.

craig tn

Can you connect you voltage meter to the battery pack and drive it around? See how low the voltage drops while riding. I would guess it is time for new batteries. Sounds to me like the batteries are weak cause the controller to shut down.

kabinski

Right before driving, it read 50.1v. While driving at full speed on level pavement, it fluctuated between 47.4-47.7. Most of the time it stayed at about 47.5. From a dead stop, when I pressed the pedal down quickly to the floor, the voltage dipped to 43.5 before leveling out at approx. 47.5 while traveling at full speed. After about 10-minutes of continuous riding, it died completely. I flipped the tow switch and waited about 5-minutes. I flipped it back and the cart worked again. I didn't drive it far after that, only about 50 yards to get it back in the garage.

craig tn

Time for new batteries.

kabinski

Thanks for your help, Craig. I've been troubleshooting this thing the best I can for a few weeks now. New batteries it is.