1999 series cart

HOOD 1

Member
I am working on a 99 series cart. Pack voltage is 50.5, cables clean, connections tight. Cart will barely move when gas is pressed. Next time it will run but when the pedal is all the way down it will gradually speed up and run at variable speed with the pedal in one place. Next time, it will barely move again. Sol. is engaging every time. Is there a test procedure for the controller? Also replaced v-glide housing, micro switch and wiper brush due to wear, but did not help.Never had a sol. cause this, Any help would be appreciated
wallbash.gif
 

golfdog

Member
Is your car a (DS or Villager 4) or is it a (Turf or Carryall) as they have differant controllers, The former has 3 large and 3 small terminals and the latter 4 large and 3 small terminals.?. Make sure the potentiometer is working correctly. Check by disconnecting the batteries and seperate the 3 pin connector from the potentiometer. Place a multimeter set to 20k ohms across the purple and yellow wire connector pins on the potentiometer side of the connector.
Negative to purple and positive to yellow With the accelerator pedal up the reading should be 0 ohms. As you depress the pedal the ohms sould rise in 6 steps from +- 910 ohms to +- 5570 ohms. (Max. reading should not exceed 7000 ohms.) If not then either the wiper arm is not making good contact, the micro switch in the pot is faulty or there may be failed resistors in the pot.
tip.gif
 

HOOD 1

Member
Thanks, I will try that tonight. I replaced the entire v-glide but reused the resistors, Could be a faulty one. The controller has 3 large and 3 small.
 

golfdog

Member
If the v-glide is operating correctly,you can check the controllers output by connecting a multimeter set to 200v DC across the B+(red probe) and M- (black probe) terminals of the controller and with the accelarator pressed to the floor (with the key switched on and the selector in fwd), the reading should show full battery voltage (+-50v) if not the controller has failed. You will of course need to firstly disconnect the A2 terminal on the motor to prevent the cart from roaring off into the beyond.It is normal practice to disconnect the batteries and discharge the capacitor before removing the A2 cable to prevent any chance of a short circuit. Once you have ensured that A2 cable is not going to touch any metalic parts of the cart, reconnect the batteries and proceed with the test.
You can also at the same time check the input voltage by removing the red 18 gauge wire from the controller terminal #1 and connecting the multimeter set for 200vDC to the B- terminal of the controller (black probe) and the red probe to the terminal end of the disconnected red wire. With the accelarator pressed down the solenoid should click and the voltage reading should be full battery voltage. .
tip.gif
 
Top