Club Car DS series 99 pedal range problem !

voodoocr

Just upgraded my cart with new (bad boy) motor and heavy duty FR switch and the following problem has developed.

Motor does not switch on for the first 80% and I have virtually no range since I'm almost to the floor by then ! The resistance test on green to yellow checks out ok from 5k to 0k from pedal up to down and I get a smooth 0 to 50v when testing the pedal positive to negative with via potbox.

Also get 10k to 5k range in reverse and 0 to 25v range which corresponds to 1/2 speed but when I try reverse No motor movement.

Any ideas anybody ?

Cart Clubcar DS series 99
Motor AMD7119 (bad boy)
Speed Controller Curtis 1205-203
Heavy duty FR switch
Solenoid Allbright 48v
#2 gauge cables

BGW

__________________
This advertising will not be shown in this way to registered members.
Register your free account today and become a member on Buggies Gone Wild Golf Cart Forum

Golferdave

Do you hear the solenoid kick in
as you first touch the pedal ?

Sergio

You should also have a purple wire from the throttle to Controller B-.

Assuming Green on Terminal #2 and Yellow on Terminal #3, where are you measuring voltages like 0-25v?

voodoocr

Yes solenoid kicks in no problem.
Purple wire is present at B-.
0 to 50v measured between yellow wire and battery- when jumper between green wire.and Bat+ as per test instructions procedure.

voodoocr

Same 0-25v measured when FR switch is in reverse this showing that extra 5k resistor is adding to the 5k to 0k range in forward !

voodoocr

Green on terminal 2 yellow on 3 I think is standard

Golferdave

A good 5k - 0 ohms signal into controller at
Terminal 2 & 3
Sounding like controller

Got a solid 48v (b+) on the red wire into
the controller?
At Terminal # 1
(from micro sw on F/R sw)

Guess here, “pre-charge resistor ok”

voodoocr

Yes precharge brand new checks at 250ohms
Controller brand new rebuild by fsip and works fine on last 2k to 0 range of.pedal plenty of power.
Solid 50v on red wire into #1

Sergio

Since Club Car does not have a cart that works on a 5kΩ-0 throttle, You need to figure out if FSIP gave you a 5kΩ-0 setup.

If the Controller is setup to use the Club Car standard, it is a 0-5v 3 wire throttle.

Pull the Yellow wire OFF terminal #3 just far enough to put the voltmeter probe on the terminal while still having the terminal connected.

The Green wire on Terminal #2 provides the power to the throttle and the yellow wire should vary from 0-5v approximately (with Green and Yellow wires connected to the Controller).

If the Controller is setup for a true 5kΩ-0 2 wire rheostat mode, You will need to disconnect the purple wire and the 1/2 speed resistor setup will not work for those types of throttle.

Golferdave

Oh
New motor, F/R
& Controller