2010 Yamaha runs intermittently

cgtech · 07-04-2018, 04:41 PM

Electrical 101- first day, before lunch...

B+ = POS

B- = NEG

skullskidr · 07-05-2018, 08:09 AM

Got it! Thanks... now if I can get it to fail in a timely manner.

skullskidr · 07-08-2018, 04:22 PM

Still trying to make it fail. On B +/- at the controller I have 50.2 high and 45.3 low pulling a long hill. Is there a magic volt number where the controller just shuts down?
Thanks again for the help!

cgtech · 07-08-2018, 05:25 PM

I don't know the magic number, but a huge drop is what we are expecting (if it's a voltage related issue). 45.3v on a long hill seems good, but this doesn't accurately represent when it actually fails.

skullskidr · 07-08-2018, 06:25 PM

Here is another odd thing that may be related or not...
Cart has 49.8v at the battery pack... tried to charge it with the jw2-h2107-03 Yamaha Charger. All lights come on when it clicks and immediately goes to the green charge light. Checked continuity on wires going to B+/- charger plug... check ok. Cleaned both plug and charger contacts. Unplugged AC cord to reset charger and it lit up yellow 90% charge momentarily then went to green. Same charger I charged my working drive with two days ago. Could the gray wire cause an issue? Specifically,
Could it cause it not to charge and or cause the cart to cut out like it has been? I think it is pin #2 going to the controller.

cgtech · 07-09-2018, 02:21 AM

Since the Drive was introduced in 2007, I have never once seen the grey wire do anything like that. But hey, anything is possible.

skullskidr · 07-09-2018, 12:28 PM

I see on the schematic the gray wire is charger data receive. Does this let the controller know the charger is hooked up and signals the cart not to move?

cgtech · 07-10-2018, 02:59 AM

Since the "third pin" is touching nothing when the charger is not plugged in, disconnecting the grey wire would be a "charger not connected" state. There is no "fancy business" inside the port. Like I said, never once seen the grey wire do any stupid stuff. If you cut the whole grey wire circuit out, it would be a "charger not connected, all ok" state.

07-04-2018, 04:41 PM	#11
cgtech Over This Interview Is... Join Date: Jun 2012 Location: AZ Posts: 17,449	Re: 2010 Yamaha runs intermittently Electrical 101- first day, before lunch... B+ = POS B- = NEG

07-05-2018, 08:09 AM	#12
skullskidr Not Yet Wild Join Date: Jun 2018 Posts: 28	Re: 2010 Yamaha runs intermittently Got it! Thanks... now if I can get it to fail in a timely manner.
skullskidr Not Yet Wild Join Date: Jun 2018 Posts: 28

07-08-2018, 04:22 PM	#13
skullskidr Not Yet Wild Join Date: Jun 2018 Posts: 28	Re: 2010 Yamaha runs intermittently Still trying to make it fail. On B +/- at the controller I have 50.2 high and 45.3 low pulling a long hill. Is there a magic volt number where the controller just shuts down? Thanks again for the help!
skullskidr Not Yet Wild Join Date: Jun 2018 Posts: 28

07-08-2018, 05:25 PM	#14
cgtech Over This Interview Is... Join Date: Jun 2012 Location: AZ Posts: 17,449	Re: 2010 Yamaha runs intermittently I don't know the magic number, but a huge drop is what we are expecting (if it's a voltage related issue). 45.3v on a long hill seems good, but this doesn't accurately represent when it actually fails.

07-08-2018, 06:25 PM	#15
skullskidr Not Yet Wild Join Date: Jun 2018 Posts: 28	Re: 2010 Yamaha runs intermittently Here is another odd thing that may be related or not... Cart has 49.8v at the battery pack... tried to charge it with the jw2-h2107-03 Yamaha Charger. All lights come on when it clicks and immediately goes to the green charge light. Checked continuity on wires going to B+/- charger plug... check ok. Cleaned both plug and charger contacts. Unplugged AC cord to reset charger and it lit up yellow 90% charge momentarily then went to green. Same charger I charged my working drive with two days ago. Could the gray wire cause an issue? Specifically, Could it cause it not to charge and or cause the cart to cut out like it has been? I think it is pin #2 going to the controller.
skullskidr Not Yet Wild Join Date: Jun 2018 Posts: 28

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07-09-2018, 02:21 AM	#16
cgtech Over This Interview Is... Join Date: Jun 2012 Location: AZ Posts: 17,449	Re: 2010 Yamaha runs intermittently Since the Drive was introduced in 2007, I have never once seen the grey wire do anything like that. But hey, anything is possible.

07-09-2018, 12:28 PM	#17
skullskidr Not Yet Wild Join Date: Jun 2018 Posts: 28	Re: 2010 Yamaha runs intermittently I see on the schematic the gray wire is charger data receive. Does this let the controller know the charger is hooked up and signals the cart not to move?
skullskidr Not Yet Wild Join Date: Jun 2018 Posts: 28

07-10-2018, 02:59 AM	#18
cgtech Over This Interview Is... Join Date: Jun 2012 Location: AZ Posts: 17,449	Re: 2010 Yamaha runs intermittently Since the "third pin" is touching nothing when the charger is not plugged in, disconnecting the grey wire would be a "charger not connected" state. There is no "fancy business" inside the port. Like I said, never once seen the grey wire do any stupid stuff. If you cut the whole grey wire circuit out, it would be a "charger not connected, all ok" state.

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