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Electric Yamaha Electric Yamaha Golf Cars; G1 through "The Drive" and U-Max Utility Vehicles



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Old 10-16-2020, 05:55 PM   #1
otis30223
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Default G19 won't move

I have a 2002 G19 regen cart. I went to use it and it won't move, no solenoid operation as well. I have checked the solenoid manually and can make it engage by grounding the negative side at the connector that plugs into the controller. Also checked accelerator stop switch (good) and throttle sensor (250 ohms to 4800 at full throttle), also tested tow\run switch which is also normal. The only thing that jumps out is when checking the motor I get .6 Ohms from A1 to A2, but it shows open from F1 to F2, no short to the case or from coil to coil. I normally work on cars and most modern control modules have internal protection the prevents operation if the module see's conditions are out of normal range. Does anyone have sufficient knowledge of the internal operation of the controller to say if it's possible that the controller simply will not power up the solenoid because the field coil resistance is out of spec, or did the motor fail in such a way as to damage the controller? Any help will be greatly appreciated.
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Old 10-17-2020, 01:47 AM   #2
cgtech
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Default Re: G19 won't move

F1-f2 open is a big problem that will prevent cart from driving.
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Old 10-17-2020, 09:21 AM   #3
otis30223
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Default Re: G19 won't move

I performed a test on the motor and it does spin with A1-F1 jumped with A2-F2 jumped and 16 volts applied. So I cleaned the terminals and I do get continuity on F1-F2 and A1-A2. So with the motor ruled out I was hoping someone has a pin out of the connector at the controller so I can verify the wiring before I look at replacing the controller. The wiring diagram shows the pins and where they go to but not what the nominal voltages should be seen at the terminal. I hate doing pure resistance tests as the do not always indicate a voltage drop that might occur when the circuit is under a load.
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Old 10-17-2020, 03:09 PM   #4
otis30223
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Default Re: G19 won't move

Pinout G19 controller.pdf

I have created a pinout for the G19 to ease my finial testing which will be in the morning, will post results.
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Old 10-17-2020, 04:38 PM   #5
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Default Re: G19 won't move

G19e harness
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Old 10-17-2020, 07:15 PM   #6
otis30223
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Default Re: G19 won't move

Yes that's same schematic I used when creating the pinout chart. I have listed each pin with wire color, source of voltage and what reading I expect to find when back probing the connector. The only one I was unsure of is what reading I should see on the throttle position sensor. On a automobile the reference voltage is 5V and varies between .45V(idle) and 4.8V(full throttle) depending on the model.
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Old 10-17-2020, 10:10 PM   #7
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Default Re: G19 won't move

I test the throttle sensor disconnected from harness. (0-5,000 ohms is spec, but 150-4,600 is closer to what you'll likely see).
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Old 10-18-2020, 01:34 PM   #8
otis30223
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Default Re: G19 won't move

After running pin test found 8.9V on pin 2. The wire that feeds this pin is spliced to the same wire that feeds pin 1, so I jumped the 2 together and the controller now operates the motor as designed. I can only assume that the splice pack is corroded resulting in the voltage drop to pin 2. I will at a latter time open up the harness and see, but since the current on this line is limited by the 3 amp inline fuse I feel that the repair made will suffice. Hope the chart created will help someone in the future.
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