2000 ds only runs on charger

DavidBreeze · 10-18-2019, 02:41 PM

I bought a 2000 ds 48 volt that was running but needed new brakes, batteries,battery wires, etc, including a new body. Everything was done and it drove around for a couple of days just fine.
I plugged in the charger and went out of town for a week. Upon return the charger indicated full charge and 55 volts.
But it would not go either forward or reverse.
I checked the battery pack with a multimeter and read 55 volts.
Wierd thing is if the charger is plugged in it runs great!
I drove it around the barn with a big extension cord.
Using shotgun diagnosis I replaced the solenoid and resistor with new, but that didn’t change anything.

Any help greatly appreciated!
David Breeze

scottyb · 10-18-2019, 02:46 PM

Logic says you have a battery problem. Or you need a lot more extension cords

Connect your voltmeter to the battery pack and try to go. What is the battery voltage dropping to when you try to go?

Mooncarter · 10-18-2019, 04:34 PM

That cart should not run with the charger plugged in. Unless somebody has bypassed the OBC. i think you will find the problem at the charging port, the OBC, or the way it has been bypassed.

55 volts. Is the charger running or just plugged in?

DavidBreeze · 10-18-2019, 05:42 PM

I’ll try reading the voltage tomorrow.
The attached pic shows the original batteries being charged, volts on top, amps below. The right side led turns green when fully charged.
Right now the volts read 55 and amps read 0, so I assume the charger thinks that the batteries are fully charged. Right side led is green.

David Breeze

I haven’t figured out how to attach the pic which I have uploaded.

yawood · 10-18-2019, 06:13 PM

Quote:

Originally Posted by DavidBreeze

I’ll try reading the voltage tomorrow.
The attached pic shows the original batteries being charged, volts on top, amps below. The right side led turns green when fully charged.
Right now the volts read 55 and amps read 0, so I assume the charger thinks that the batteries are fully charged. Right side led is green.

David Breeze

I haven’t figured out how to attach the pic which I have uploaded.

That is not a PowerDrive charger so I would say that someone has already bypassed the OBC.

When you say everything was done, who did it?

DavidBreeze · 10-20-2019, 05:20 PM

5EE55111-12CA-4A4D-8E84-11663C47916C.jpg

74134A8D-1250-4FF6-A876-75B36F055FBB.jpg

F5E681D6-B44E-4265-9344-5DCFB3DD119D.jpg

DavidBreeze · 10-20-2019, 05:43 PM

The charger came with the cart.
It worked with the old batteries and I think it works with the new.
It appears to be a Ron’s DL-900W, which I can only find on Alibaba.
Anyhow
The cart spent it’s service life inside the Toyota factory here in KENTUCKY.
It was then sold to the farmer that I bought it from.
I think half of his farm was up in the cart when I got it!
But it did run.
I personally replaced the shocks, bushings, 2 leaf springs and bushings,
Brake drums, brake shoes, brake cables, most of the linkage underneath, as well as both body cowls, fasteners, and head lights and tail lights.
I also installed a voltage reducer to run the lights and horn.
Crimeny
When I received the cart there was a blue wire running from the upper right contact of the charger, to the negative of the last battery in the pack.
It is not on the wiring chart, so after I returned from the trip I disconnected it from the battery.
More later, I have to cook dinner
David Breeze

DavidBreeze · 10-20-2019, 07:26 PM

Umm, good dinner
So
I did the voltage drop test
Read 48 volts, switched on key and forward switch, depressed the go pedal, and read 38 volts.
After returning from the trip and nothing working, I took out the page that was inside the charger box. See the pic.
It said to run a wire from the upper left hand side of the charger to the negative side of the first battery in the battery pack.
I did that but still have no go.
I wonder if the wire on the same charger terminal, which runs to the obc should be removed.?

My sage advice to anyone right now is never buy a very used cart!

Thanks again for any advice
David Breeze

Mooncarter · 10-20-2019, 07:36 PM

What is your pack voltage, 55 volts or 48 volts? Take your voltage meter and report back the exact voltage.

DavidBreeze · 10-21-2019, 12:27 PM

Ok,
The charger has been unplugged for about a week.
The battery pack read 46.
With key on and forward switch, volts drop to 37 when go pedal pushed.
With charger plugged in volts read 55.
After 4 hours charging, pack reads 50 volts.

David Breeze

10-18-2019, 02:41 PM	#1
DavidBreeze Not Yet Wild Join Date: Oct 2019 Posts: 11	2000 ds only runs on charger I bought a 2000 ds 48 volt that was running but needed new brakes, batteries,battery wires, etc, including a new body. Everything was done and it drove around for a couple of days just fine. I plugged in the charger and went out of town for a week. Upon return the charger indicated full charge and 55 volts. But it would not go either forward or reverse. I checked the battery pack with a multimeter and read 55 volts. Wierd thing is if the charger is plugged in it runs great! I drove it around the barn with a big extension cord. Using shotgun diagnosis I replaced the solenoid and resistor with new, but that didn’t change anything. Any help greatly appreciated! David Breeze
DavidBreeze Not Yet Wild Join Date: Oct 2019 Posts: 11

10-18-2019, 02:46 PM	#2
scottyb Happy Carting Join Date: Dec 2007 Location: Southern California Posts: 73,406	re: 2000 ds only runs on charger Logic says you have a battery problem. Or you need a lot more extension cords Connect your voltmeter to the battery pack and try to go. What is the battery voltage dropping to when you try to go?

10-18-2019, 04:34 PM	#3
Mooncarter Gone Insane Join Date: Oct 2016 Location: Richmond, VA Posts: 14,214	re: 2000 ds only runs on charger That cart should not run with the charger plugged in. Unless somebody has bypassed the OBC. i think you will find the problem at the charging port, the OBC, or the way it has been bypassed. 55 volts. Is the charger running or just plugged in?

10-20-2019, 05:20 PM	#6
DavidBreeze Not Yet Wild Join Date: Oct 2019 Posts: 11	Re: 2000 ds only runs on charger 5EE55111-12CA-4A4D-8E84-11663C47916C.jpg 74134A8D-1250-4FF6-A876-75B36F055FBB.jpg F5E681D6-B44E-4265-9344-5DCFB3DD119D.jpg
DavidBreeze Not Yet Wild Join Date: Oct 2019 Posts: 11

10-20-2019, 05:43 PM	#7
DavidBreeze Not Yet Wild Join Date: Oct 2019 Posts: 11	Re: 2000 ds only runs on charger The charger came with the cart. It worked with the old batteries and I think it works with the new. It appears to be a Ron’s DL-900W, which I can only find on Alibaba. Anyhow The cart spent it’s service life inside the Toyota factory here in KENTUCKY. It was then sold to the farmer that I bought it from. I think half of his farm was up in the cart when I got it! But it did run. I personally replaced the shocks, bushings, 2 leaf springs and bushings, Brake drums, brake shoes, brake cables, most of the linkage underneath, as well as both body cowls, fasteners, and head lights and tail lights. I also installed a voltage reducer to run the lights and horn. Crimeny When I received the cart there was a blue wire running from the upper right contact of the charger, to the negative of the last battery in the pack. It is not on the wiring chart, so after I returned from the trip I disconnected it from the battery. More later, I have to cook dinner David Breeze
DavidBreeze Not Yet Wild Join Date: Oct 2019 Posts: 11

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10-20-2019, 07:26 PM	#8
DavidBreeze Not Yet Wild Join Date: Oct 2019 Posts: 11	Re: 2000 ds only runs on charger Umm, good dinner So I did the voltage drop test Read 48 volts, switched on key and forward switch, depressed the go pedal, and read 38 volts. After returning from the trip and nothing working, I took out the page that was inside the charger box. See the pic. It said to run a wire from the upper left hand side of the charger to the negative side of the first battery in the battery pack. I did that but still have no go. I wonder if the wire on the same charger terminal, which runs to the obc should be removed.? My sage advice to anyone right now is never buy a very used cart! Thanks again for any advice David Breeze
DavidBreeze Not Yet Wild Join Date: Oct 2019 Posts: 11

10-20-2019, 07:36 PM	#9
Mooncarter Gone Insane Join Date: Oct 2016 Location: Richmond, VA Posts: 14,214	Re: 2000 ds only runs on charger What is your pack voltage, 55 volts or 48 volts? Take your voltage meter and report back the exact voltage.

10-21-2019, 12:27 PM	#10
DavidBreeze Not Yet Wild Join Date: Oct 2019 Posts: 11	Re: 2000 ds only runs on charger Ok, The charger has been unplugged for about a week. The battery pack read 46. With key on and forward switch, volts drop to 37 when go pedal pushed. With charger plugged in volts read 55. After 4 hours charging, pack reads 50 volts. David Breeze
DavidBreeze Not Yet Wild Join Date: Oct 2019 Posts: 11

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