1996 G19 won't run

trentofdestiny · 07-25-2019, 07:59 AM

I bought this cart for a friend and he's trying to make it run. It appears to have a G22 style controller, where all the terminals are on the top of the controller not on the end.

Got the cart with solenoid missing. Installed new solenoid, reverse buzzer worked but solenoid didn't cycle.

Tested all the wiring according to FSIP troubleshooting guide. Motor resistance was a little higher than FSIP said (like 0.5 ohm high or something like that) but not shorted to each other or to case.

Friend took the controller to be rebuilt for $270 and they said there was a short in the armature or field section of the controller. He put it back on and said it still doesn't work. Does he need a motor?

TXWELDER · 07-25-2019, 02:47 PM

What’s the pack voltage?

trentofdestiny · 07-25-2019, 04:18 PM

Quote:

Originally Posted by TXWELDER

What’s the pack voltage?

He said it was 49 or 50 volts before rebuilding the controller. It didn't even try to move or engage the solenoid, before or after rebuild.

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TXWELDER · 07-26-2019, 10:50 AM

I’d be concerned if the cart is complete and connections are made properly.

trentofdestiny · 07-26-2019, 11:29 AM

Quote:

Originally Posted by TXWELDER

I’d be concerned if the cart is complete and connections are made properly.

I believe all the connections are done properly. Unless the solenoid coil wires are swapped but I don't think that would make a difference. Solenoid works when tow switch is in run and you give it ground. Controller is not turning it on

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cgtech · 07-28-2019, 02:14 PM

If the controller isn't activating the solenoid, and it's been shown that B+ is getting from the tow/run to the solenoid small red, the controller should be turning it on. Does the controller attempt to keep the cart from rolling away if you push it? I'm starting to think that maybe the controller isn't correct for a Yamaha, or has other problems.

trentofdestiny · 07-28-2019, 02:31 PM

Quote:

Originally Posted by cgtech

If the controller isn't activating the solenoid, and it's been shown that B+ is getting from the tow/run to the solenoid small red, the controller should be turning it on. Does the controller attempt to keep the cart from rolling away if you push it? I'm starting to think that maybe the controller isn't correct for a Yamaha, or has other problems.

He told me that the speed sensor was also bad, because it tested bad. According to the instructions, one lead should be 12v, one should be about 4.5v, one should be ground, with the sensor unplugged. Al 3 leads read 12v with the sensor plugged in which is wrong but the sensor doesn't read shorted with the ohmmeter.

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trentofdestiny · 07-28-2019, 02:33 PM

These are the instructions we are using.

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cgtech · 07-28-2019, 03:16 PM

Those might be great & all, but I don't use those. I been certified by Yamaha, and been working at a Yamaha dealer for over 11 years.

trentofdestiny · 07-28-2019, 03:20 PM

Quote:

Originally Posted by cgtech

Those might be great & all, but I don't use those. I been certified by Yamaha, and been working at a Yamaha dealer for over 11 years.

What would you use then? I have a full service manual for G22 and I went through the troubleshooting section on that which led us to the controller. I did not look for anything on the speed sensor though.

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07-25-2019, 07:59 AM	#1
trentofdestiny Gone Wild Join Date: Oct 2017 Location: Harrisburg, PA Posts: 380	1996 G19 won't run I bought this cart for a friend and he's trying to make it run. It appears to have a G22 style controller, where all the terminals are on the top of the controller not on the end. Got the cart with solenoid missing. Installed new solenoid, reverse buzzer worked but solenoid didn't cycle. Tested all the wiring according to FSIP troubleshooting guide. Motor resistance was a little higher than FSIP said (like 0.5 ohm high or something like that) but not shorted to each other or to case. Friend took the controller to be rebuilt for $270 and they said there was a short in the armature or field section of the controller. He put it back on and said it still doesn't work. Does he need a motor?

07-25-2019, 02:47 PM	#2
TXWELDER Gone Wild Join Date: Apr 2019 Posts: 198	Re: 1996 G19 won't run What’s the pack voltage?
TXWELDER Gone Wild Join Date: Apr 2019 Posts: 198

07-26-2019, 10:50 AM	#4
TXWELDER Gone Wild Join Date: Apr 2019 Posts: 198	Re: 1996 G19 won't run I’d be concerned if the cart is complete and connections are made properly.
TXWELDER Gone Wild Join Date: Apr 2019 Posts: 198

07-28-2019, 02:14 PM	#6
cgtech Over This Interview Is... Join Date: Jun 2012 Location: AZ Posts: 17,449	Re: 1996 G19 won't run If the controller isn't activating the solenoid, and it's been shown that B+ is getting from the tow/run to the solenoid small red, the controller should be turning it on. Does the controller attempt to keep the cart from rolling away if you push it? I'm starting to think that maybe the controller isn't correct for a Yamaha, or has other problems.

07-28-2019, 02:33 PM	#8
trentofdestiny Gone Wild Join Date: Oct 2017 Location: Harrisburg, PA Posts: 380	Re: 1996 G19 won't run These are the instructions we are using. Sent from my iPhone using Tapatalk

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07-28-2019, 03:16 PM	#9
cgtech Over This Interview Is... Join Date: Jun 2012 Location: AZ Posts: 17,449	Re: 1996 G19 won't run Those might be great & all, but I don't use those. I been certified by Yamaha, and been working at a Yamaha dealer for over 11 years.

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