1999 par car

bigbob1736

Hi guys have 99 par car I get a solid green on my sevcon controller. But nothing happens. Sometimes I can get it to go forward and times it doesn't do anything.There is a new keyswitch, toggle switch,solenoid and the motor has been checked out and it is great shape. Does anyone have any idea what could be wrong I'm leaning towards the pot box. Plus I never can get to go reverse. I get two flashes which means illegal start.

BGW

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Tech Support

When you select a direction, the switch has to close for either forward or reverse, before the pedal is pressed. When you press the pedal, the microswitch on the pot box has to close first, before any resistance is read. Anything out of order will throw a 2 flash.

You can should have the older wiring harness with the open backed 16 pin connector at the controller, instead of the sealed black molded end we use now. You can check the switch actions at that 16 pin controller by inserting volt meter probe into back of controller plug.

Don't use chassis as ground, use an alligator clip and the negative battery connection right at the controller. It's stamped B-.

Then with the key on, first off you should have 48volts (assuming a 48V vehicle) at pin 1 of the controller. (See attached photo for pin id).

When measuring the switch results, when they are NOT selected they should have logic 5 volt positive. When selected they take that pin to B- so there would be zero volts.

Pin 2 is the forward switch. (When you select forward, pin 2 goes to 0)
Pin 3 is the reverse switch. (When you select reverse, pin 3 goes to 0)
Pin 4 is the pedal/potbox microswitch. (When you press the pedal, pin 4 will go to 0)
Pin 10 is the actual potbox input, but you could read the 0-5K ohms at the potbox wiring itself.

Attached Files

Pages from Controller Hookup.pdf (17.1 KB, 0 views)

bigbob1736

Thank you for the info. I will working on it in few days and I will let you know what I come up with. Thanx again.

bigbob1736

I did what you said to do
When I put it in reverse I got 36v reading. Zero readings on all other test. Could it be the pot box . Again thank you again for the info.

Tech Support

So now I'm assuming it's a 36volt unit. The wheels shouldn't jerk when you select a gear, as there shouldn't be any potbox signal at that point. You may have a bad potbox.

bigbob1736

im leaning the same way. It jerks when I just turn the key on without selecting forward or reverse. These are two different switches on is power and the other is forward/reverse switch. Yes its 36v.

bigbob1736

I forgot to say I don't get 5 volts on forward pin 2 reverse pin 3 always reads 36 volts. Still could it be The pot box.

bigbob1736

Sorry I said when I put it reverse I get 36v. I meant when it's in forward pin 3 reads 36( which is reverse) thanks again