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Unread 10-07-2008, 11:07 PM   #21
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Default Re: potentiometer

dont have pics of original controller threw it out last year, after ripping it apart and finding 3 mosfets and four capacitors black and melted.
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Unread 10-07-2008, 11:54 PM   #22
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Default Re: potentiometer

It did ring a bell when you said 400 amp controller, seems like I remember seing that written on original curtis controller, and telling the folks from buggies unlimited, they said upgrading to their 720 amp controller there would be no problem.
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Unread 10-08-2008, 01:58 AM   #23
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Default Re: potentiometer

PC4X,
I hate to say this but man clean that wiring up. I can't make heads or tails out of it.
What is the wire nut holding together? That cable doesn't look factory at all to me.
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Unread 10-08-2008, 09:08 AM   #24
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Default Re: potentiometer

Does the cart have an onboard battery charger? Assuming yes based on the wires running to the #6 negative post and the #1 positive post.
Is there anything wire or fuse terminal block that is contacting the frame creating a ground? Based on the condition of the wiring and how dirty everything is you may be getting a ground condition and that is taking the controller out over time.
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Unread 10-08-2008, 07:29 PM   #25
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Default Re: potentiometer

andy 4639
the wire nut was a splice from the onboard charger it was existing when I purchased the cart a year and a half ago.

After cleaning cables walllla there is a resistor on the solenoid between the two large posts rated 250 ohms, tested at 249.2 ohms. I looked back at my notes from when I installed the heavy duty solenoid and controller. and listed is this 250 ohm resistor and the diode. however you say there was another resistor neccessary to controller what are its specs and where does it go?

I live on a farm in florida rain every day, and dust and sand are a constant battle. This dirt accumulation is only three weeks old. to combat this problem all electrical conections are triple coated with electrical protectant purchased from the ez-go dealer about every 4 months.

Paxdad
I have checked for any bare or rubbed coatings on wires and have found everything in good condition.

also wires from tail lights and backup horn were disconetted when I purchased the cart. I have not reconected because several are shorted out and I am unable to find the appropriate bulbs that are burnt.
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Unread 10-08-2008, 07:36 PM   #26
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Default Re: potentiometer

pics
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Unread 10-08-2008, 07:40 PM   #27
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Default Re: potentiometer

Can you post a picture of the controller that I can see what wires go to? I just can't for the life of me seeing a pot box burning up a controller. Something is not right. If you have the small diode and resister on the selonoid your fine. It's the same thing as on the controller.
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Unread 10-08-2008, 09:03 PM   #28
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Default Re: potentiometer

this is how wires are hooked up.

A post on fnr to A2 on controller ,,,onward to A2 on motor

#1 batter + to solenoid+ to through solenoid and resitor to B+,,, onward to A1 on motor.

B post on fnr to S1 on motor

C post on fnr to M1 on controller

D post on fnr to S2 on motor

main ground to B- on contorller
B- small black wire to solenoid

Blue wire on controller to micro on top of potentiometer on same post with yellow wire straight to key switch, previous owner bipassed fnr micro switch.

orange wire from (potentiometer) micro to solenoid and diode.

previous owner bipassed or disconected all fnr microswitches.
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Unread 10-08-2008, 09:16 PM   #29
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Default Re: potentiometer

In the photo it appears that there are two black cables running from the solenoid one going to the controller and the other going to ?? I am including a couple of photos of my sytem for a reference. There should also be a resistor across the controller B+ and B-.

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Unread 10-08-2008, 09:30 PM   #30
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Default Re: potentiometer

You really need to return the system back to its orignal wiring scheme in addition to getting the micro switches back in the loop. Keep in mind as far as the microswitches go they complete the signal for the back up alarm and half speed reverse (if hooked up from the potentiometer), and the other completes signal for potentiometer to the controller.
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