Controller failure?

SHOTGUNN · 10-26-2016, 11:48 AM

Hi, I would like to confirm if a 94 medalist series style controller is bad. I have checked out all the basics and have gone through the troubleshooting chart till the last step and have a result that does not show in the chart. So in step 7 of my chart( key on, f/r in neutral volt meter on B+ and M- and no pedal depression) there should be 0v between b+ and m-, mine has 36v. When shifted into forward or reverse the voltage goes to 0 bewtween b+ and m- then when pedal is depressed no voltage increase is present. All checks before this final were within spec. Thoughts?

scottyb · 10-26-2016, 12:01 PM

There is more than one way to skin this cat. I check mine a little differently - place test leads on B- and M-. When the solenoid clicks it should read 36v and as the pedal is depressed this number should go down near 0v.

SHOTGUNN · 10-26-2016, 12:12 PM

Thanks, just tried that in forward and 36v present between b- and m- when the solenoid clicks, but volts do not drop when pedal is depressed further.

scottyb · 10-26-2016, 12:33 PM

Assuming solenoid is clicking and working, you have to verify 2 more things; the controller is powered up = 36v+ to red wire pin #1 (stock control) and throttle signal is present and correct.

SHOTGUNN · 10-26-2016, 01:31 PM

Have tested those in the troubleshooting sequence and all were within spec, I will double check them though.

SHOTGUNN · 10-26-2016, 03:59 PM

Went through my tests again, only found one thing odd. When checking the white wire at the controller the check tells me to have a jumper from b+ to + solenoid coil post. key on and in forward. Then press the pedal here a click (picture shows micro switch) and then take readings on white wire sweeping the pedal. The odd thing I have is that solenoid with the jumper is already engaged and before i press the pedal and activate the micro switch the white wire is already showing voltage(proper spec). The sweep voltage if fine also.

scottyb · 10-26-2016, 04:34 PM

Well if by sweep (pedal up to pedal down? ) voltage is within range then consider the controller dead. It is being told to pass amperage to the motor and it is not.

SHOTGUNN · 10-26-2016, 04:46 PM

Okay thanks

10-26-2016, 11:48 AM	#1
SHOTGUNN Not Yet Wild Join Date: Jul 2013 Posts: 5	Controller failure? Hi, I would like to confirm if a 94 medalist series style controller is bad. I have checked out all the basics and have gone through the troubleshooting chart till the last step and have a result that does not show in the chart. So in step 7 of my chart( key on, f/r in neutral volt meter on B+ and M- and no pedal depression) there should be 0v between b+ and m-, mine has 36v. When shifted into forward or reverse the voltage goes to 0 bewtween b+ and m- then when pedal is depressed no voltage increase is present. All checks before this final were within spec. Thoughts?
SHOTGUNN Not Yet Wild Join Date: Jul 2013 Posts: 5

10-26-2016, 12:01 PM	#2
scottyb Happy Carting Join Date: Dec 2007 Location: Southern California Posts: 73,417	Re: Controller failure? There is more than one way to skin this cat. I check mine a little differently - place test leads on B- and M-. When the solenoid clicks it should read 36v and as the pedal is depressed this number should go down near 0v.

10-26-2016, 12:12 PM	#3
SHOTGUNN Not Yet Wild Join Date: Jul 2013 Posts: 5	Re: Controller failure? Thanks, just tried that in forward and 36v present between b- and m- when the solenoid clicks, but volts do not drop when pedal is depressed further.
SHOTGUNN Not Yet Wild Join Date: Jul 2013 Posts: 5

10-26-2016, 12:33 PM	#4
scottyb Happy Carting Join Date: Dec 2007 Location: Southern California Posts: 73,417	Re: Controller failure? Assuming solenoid is clicking and working, you have to verify 2 more things; the controller is powered up = 36v+ to red wire pin #1 (stock control) and throttle signal is present and correct.

10-26-2016, 01:31 PM	#5
SHOTGUNN Not Yet Wild Join Date: Jul 2013 Posts: 5	Re: Controller failure? Have tested those in the troubleshooting sequence and all were within spec, I will double check them though.
SHOTGUNN Not Yet Wild Join Date: Jul 2013 Posts: 5

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10-26-2016, 03:59 PM	#6
SHOTGUNN Not Yet Wild Join Date: Jul 2013 Posts: 5	Re: Controller failure? Went through my tests again, only found one thing odd. When checking the white wire at the controller the check tells me to have a jumper from b+ to + solenoid coil post. key on and in forward. Then press the pedal here a click (picture shows micro switch) and then take readings on white wire sweeping the pedal. The odd thing I have is that solenoid with the jumper is already engaged and before i press the pedal and activate the micro switch the white wire is already showing voltage(proper spec). The sweep voltage if fine also.
SHOTGUNN Not Yet Wild Join Date: Jul 2013 Posts: 5

10-26-2016, 04:34 PM	#7
scottyb Happy Carting Join Date: Dec 2007 Location: Southern California Posts: 73,417	Re: Controller failure? Well if by sweep (pedal up to pedal down? ) voltage is within range then consider the controller dead. It is being told to pass amperage to the motor and it is not.

10-26-2016, 04:46 PM	#8
SHOTGUNN Not Yet Wild Join Date: Jul 2013 Posts: 5	Re: Controller failure? Okay thanks
SHOTGUNN Not Yet Wild Join Date: Jul 2013 Posts: 5

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