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Old 07-25-2013, 02:33 PM   #1
miketuite
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Default I Killed My G22E!

Hello,

I wanted to install a battery charge meter on my G22E and, at the suggestion of someone whose knowledge I respect, I spliced into the pack negative at the light switch and the pack positive at the key switch. I cut those two wires, spliced in a “pigtail” and connected them to the battery charge meter. I tried it, and nothing. I removed the splices and reconnected the original wires. Nothing on the cart works other than the lights.

I did touch two wires and caused a spark while I was splicing, so I replaced the fuse to no avail (it wasn't blown.) My multi-meter says there's 8v at the key switch. There were 42v before I started.
Before I started my "project," I was getting 50v on the multi-meter across the battery pack. I just fully charged the batteries and now I'm getting 42v across the pack. They are 1-year-old Trojans. Each battery is reading 8.5v but the reading for the whole pack is 42v? The reading at the + and – wires I originally spliced into is down to 8v.
I’m sorry if this is confusing, but I’m a total newbie. If anyone has an idea about the next steps I should take, I’d really appreciate hearing them.

Thanks in advance,

Mike
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Old 07-25-2013, 06:20 PM   #2
simple man
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Default Re: I Killed My G22E!

Try measuring your pack voltage directly from the batteries. ( if you aren't already )
Also double check that the connections you made were on the 48V side of the voltage reducer. From what you've said, the soc meter should have worked. You may have burned open a wire in your harness. let us know what you find.
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Old 07-25-2013, 11:31 PM   #3
cgtech
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Default Re: I Killed My G22E!

look around for a fuse under the rear cover where the motor controller is located (3A purple). it will be inside a weather-proof boot. if the fuse you found was 10,15,or 20 amp, it likely was for the lights, not the motor controller. if the fuse you found was accessible from under the seat, it likely is not the controller fuse. look under the black rear "yamaha" cover. the lights and controller are always on seperate fuses, so pull the fuse you already found, and see if your lights quit working.
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Old 07-26-2013, 11:44 AM   #4
miketuite
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Default Re: I Killed My G22E!

Thanks for your help, gents. Hopefully, I'm getting closer, but no cigar yet. The 15A fuse is definitely for the lights. I found the 3A fuse and it was blown. I replaced it, but there's no change in the "symptoms." No solenoid click and, of course, no motor action.

I checked the pack voltage directly from the batteries, and the multi-meter reads 42V. As I said earlier, it was reading 50V before I started my project. Checked separately, each battery reads 8.5V.

Any suggestions as to what to try next would be greatly appreciated.

Thanks again,

Mike
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Old 07-26-2013, 05:42 PM   #5
simple man
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Default Re: I Killed My G22E!

If each battery is reading 8.5V, you should have 51V for a total! Double check all your battery connecting cables and their terminals.
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Old 07-26-2013, 08:47 PM   #6
ma_tty_d
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Default Re: I Killed My G22E!

Quote:
Originally Posted by miketuite View Post
Hello,

I wanted to install a battery charge meter on my G22E and, at the suggestion of someone whose knowledge I respect, I spliced into the pack negative at the light switch and the pack positive at the key switch. I cut those two wires, spliced in a “pigtail” and connected them to the battery charge meter. I tried it, and nothing. I removed the splices and reconnected the original wires. Nothing on the cart works other than the lights.

I did touch two wires and caused a spark while I was splicing, so I replaced the fuse to no avail (it wasn't blown.) My multi-meter says there's 8v at the key switch. There were 42v before I started.
Before I started my "project," I was getting 50v on the multi-meter across the battery pack. I just fully charged the batteries and now I'm getting 42v across the pack. They are 1-year-old Trojans. Each battery is reading 8.5v but the reading for the whole pack is 42v? The reading at the + and – wires I originally spliced into is down to 8v.
I’m sorry if this is confusing, but I’m a total newbie. If anyone has an idea about the next steps I should take, I’d really appreciate hearing them.

Thanks in advance,

Mike
check the voltage at each side of the switch, if you touched wires after the switch together, then you could have melted the contacts inside the switch before the fuse blew.

the first thing i would try is just disconnect the switch completely and put the multimeter in 10A mode between the two wires, with any luck, the cart will come alive!
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Old 07-27-2013, 02:32 PM   #7
miketuite
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Default Re: I Killed My G22E!

Thanks guys,

Here's what I did ... but remember I'm a rank novice.

1. The battery connections look fine and are tight. Just to be sure, I hit each terminal with a little anti-corrosion oil. I'm still getting a 42V reading across the battery pack.

2. There are two wires coming out of my key switch, one red and the other red with white stripes. I'm assuming that one brings power into the switch and the other brings it out. In other words, one wire is before the switch and the other is after. Right?

I removed the key switch and touched the two wires (before the switch) together ... and nothing. I then checked each of the two red/striped wires - separately - and a ground with the multi-meter and read 8V on each of them.

I'm sorry if I'm a PIA, but I really appreciate your help.

Thanks,

Mike
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Old 07-27-2013, 02:54 PM   #8
simple man
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Default Re: I Killed My G22E!

Check each battery separately and see what you read for each battery. You have an extreme loss of power somewhere in your battery pack. If all the batteries check out ( should read 8.41V to 8.49V = 90% to 100% soc ), I would remove and clean each cable one by one. Check them very carefully for any signs of melted insulation or black coloration. Any that look like that should be replaced!
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Old 07-27-2013, 07:33 PM   #9
miketuite
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Default Re: I Killed My G22E!

simple man,

The batteries each read 8.5 plus or minus a couple of hundredths. The loss of voltage makes no sense to be. Especially since the pack read 50V just before (minutes before) I started my project. I'll remove and clean the cables and terminals tomorrow.

Thanks again for your help.

Mike
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Old 07-27-2013, 07:51 PM   #10
ma_tty_d
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Default Re: I Killed My G22E!

Quote:
Originally Posted by miketuite View Post
simple man,

The batteries each read 8.5 plus or minus a couple of hundredths. The loss of voltage makes no sense to be. Especially since the pack read 50V just before (minutes before) I started my project. I'll remove and clean the cables and terminals tomorrow.

Thanks again for your help.

Mike
Mike, with the switch in the on position, Wiggle each cable individually, only gently, back and forth, up and down. If a cable is faulty, sometimes wiggling it can make contact and shed some light on where the fault is.

when the cart is put on the charger, does the charger give an error? if so a cable could have gone high resistance. cheers
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