1999 TXT will not go

[smott04]

I have a 1999 TXT series motor that will not go. I found some wires burnt and replaced all of my wires with size 2 welding cable. Now cart will not move. The solenoid will click but no move. The BU-500L controller will blink 4 times green then go red.

The cart has the following changes:
Motor: High speed or low torque controled by switch
Controller: BU-500L
Solenoid: Whit-Rogers 124-11711
Tires: 20"
Lift: 4"
Flip Seat
Pack Voltage: 36.55
Voltage from Bat Pos to Controller side of Solenoid:35.17

Please help.

[JohnnieB]

Welcome to BGW!

First and foremost, charge those batteries.
Their State of Charge is only 55% and the plates are sulfating as we speak.
When they are fully charged (38.2V after a 12 hour rest - Higher if sooner):
What is the voltage between Negative terminal on Right-Rear battery and Battery side main terminal on controller?
What is the voltage between Negative terminal on Right-Rear battery and Controller side main terminal on controller when solenoid is activated?

FWIW: this voltage reading "Voltage from Bat Pos to Controller side of Solenoid:35.17", tells me the solenoid is not activated, is bad or there is a bad high current cable between B+ on pack and solenoid; And the MOSFETs in the controller are either shorted or turned on.

[smott04]

Here is what I got this morning after recharging nthe batteries.

Main pack-38.00
Bat Neg to B+ on controller - 36.55
Bat Neg to B- on Controler - 37.96
B- on Controller to M- on Controller - 18.81 when dirt pushed and goes down to zero.

Any help will be appreciated.

[scottyb]

Originally Posted by smott04

Here is what I got this morning after recharging nthe batteries.

Main pack-38.00
Bat Neg to B+ on controller - 36.55
Bat Neg to B- on Controler - 37.96
B- on Controller to M- on Controller - 18.81 when dirt pushed and goes down to zero.

Any help will be appreciated.

That sounds like a controller failure.

[smott04]

Are there any others tests I can run before spending money on the controller? Is there a way to bypass it to make motor is not bad?

I just want to make sure I have done all I can to make sure I am replacing the correct part.

[JohnnieB]

Originally Posted by smott04

Here is what I got this morning after recharging nthe batteries.

1. Main pack-38.00
2. Bat Neg to B+ on controller - 36.55
3. Bat Neg to B- on Controler - 37.96
4. B- on Controller to M- on Controller - 18.81 when dirt pushed and goes down to zero.

Any help will be appreciated.

1. Don't know time lapse between when charger turned off and voltage reading taken, but probably less than 12 hours, so this is a bit low and you may have some battery issues that will need to be addressed in the future, but 38.00V is high enough to run cart around the block a few times.

2. If the solenoid isn't activated and 250 Ohm resistor is installed across contacts, this is okay. If solenoid is activated (Contacts closed), you are loosing 1.45 Volts and that needs to be corrected. (Bad cables, bad contacts in solenoid, dirty/corroded/loose connections)

3. This ought to read ZERO, so the cable and/or connections between Bat Neg to B- on controller is bad.

4. I'm not sure what you are trying to say by this "18.81 when dirt pushed and goes down to zero."
On the other hand, having 18.81V when pedal first pushed and dropping to zero as pedal is pushed to floor, is a very good sign.

I hate to disagree with Scotty because he has probably forgotten more about carts than I'll ever know.
But I suspect your controller is okay due to B- to M- having a voltage (only half what it ought to be) and it drops to zero as pedal is pushed.

My guess is bad cables and connections.
Of course, I'm not ruling out the controller until we get fully battery pack voltage at M-.

Get the cable/connections between Battery Negative and B- terminal on controller fixed and try again.

While you are at it, check the rest of the high current cables and clean all the connections.

[COURTESYCART]

if you had burnt wires at you f-n-r swith, more than likely it is bad. remove the switch and take it apart. you will prob notice that the brass terminals has melted into the backing plate.

[smott04]

I put in a new F N R Switch when I replaced wires and since then it has not moved.

[JohnnieB]

Originally Posted by smott04

I put in a new F N R Switch when I replaced wires and since then it has not moved.

I might have put my foot in my mouth when I disagreed with Scotty.
It is either miswired or the controller is bad.

The big red flag I see is getting a voltage drop across a single piece of cable.
Specifically: B- on battery pack to B- terminal on controller. ("Bat Neg to B- on Controler - 37.96")
Until that is straightened out, the rest of the voltage reading are suspect.

[scottyb]

Originally Posted by smott04

I put in a new F N R Switch when I replaced wires and since then it has not moved.

If the cart ran before the F&R was changed then this may be the problem area? Am I reading this right?