Pot box failure?

barcloverranch

Hello Everyone,

I once again need the assistance of someone smarter than me. I have a 1986 Ezgo Marathon equipped with the carts unlimited conversion kit, done several years ago. The cart intermittently decides not to go, and usually decides to start working again about that time I get the tools out.

Tonight I was running through the CU troubleshooting and it finally failed a test. I was testing the pot, connecting my two leads into the pot output wires to the controller. With the pedal up my reading was less than 60 and with the pedal pressed it never climbed over about 160. Solenoid clicks, controller initially flashes green followed by 3 red flashes. Not sure if the flashing is because pot is disconnected?

Anyway, do these results indicate a failure in the pot?

Thanks everyone!

BGW

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scottyb

The V1 kits prior to the spring of 2017 used a 0-5000 potentiometer. The pot is tested by setting your meter to a range of 0-20,000 Ωs and disconnecting the 2 throttle signal wires from the controller and plugging the mere into these two spades. Working the go pedal you should see close to 0-5000 ohms

barcloverranch

Scotty, so it sounds like the test you're describing is what I'm attempting to describe.

I just went out and hooked it up again and set the MM to 20k. It read 0.02 with pedal not pressed, then climbed to 0.4-0.5 pedal pressed.

This test was conducted after passing the solenoid tests you have posted on CU.

Does this indicate a failure in the pot itself?

Thanks!

scottyb

That looks like a pass.

scottyb

IF the pot signal is true the controller LED will change from green to orange at full throttle...

barcloverranch

Scotty, I just hooked up the pot wires to the controller again to check the led light and the cart is running again. I will have to drive the cart to failure again tomorrow and I will repeat the pot test then check the led light.

I will keep you posted, thank you for the replies!

barcloverranch

Also,

I was not observant when unhooking the pot signal wires from the controller, what is the order of the blue and brown wires onto the #2 and #3 controller posts?

Thanks!

mgray70

I don't think it matters, it just flows from one through the pot and back to the other. It's not like a positive and negative.

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barcloverranch

Okay everyone,

So after work today the cart is back to not running. I resumed testing, hooked up the meter to the pot signal wires, set it to 20k, and had a reading of 0.00 pedal up and 0.00 down (it momentarily flashed 0.01 a couple times but didn't maintain). Solenoid passed its test. And controller led will flash green once, followed by 3 red flashes.

Can anyone tell me what these results indicate?

mgray70

If you tested the pot correctly it sounds as if the pot is bad. I should start at 0 and smoothly go to 5k, or 5000.

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