2002 DS 48v Series NEED HELP!

[jeremykent]

Even better is there a service manual on line somewhere??

[Storm S]

Originally Posted by jeremykent

I would love to check the readings. Do you have the info how to??? I just got done running a meter on the motor and fwd rev switch. The voltage is all over the place and seems to be dead spots in the throttle

>>From The Stolen Technical Manual Direct From Curtis <<

TEST 3 Check the potbox circuitry
The following procedure applies to the standard throttle input configuration
for these controllers, which is a nominal 5kΩ pot connected as a two-wire
rheostat (0 = full off, 5 kΩ = full on), and also to 5kΩ–0 configurations.
Some 1204/1205 controllers are sold with other input characteristics. If
your installation uses a controller with a throttle input other than 0–5kΩ
or 5kΩ–0, find out what its range is and use a procedure comparable to
the one below to make sure your pedal/potbox is working correctly.

3-A With the keyswitch off, pull off the connectors going to the throttle
input of the controller. Connect an ohmmeter to the two wires going
to the potbox and measure the resistance as you move the pedal up
and down. The resistance at the limits should be within these ranges:
RESISTANCE (in ohms)
STANDARD
0–5kΩ POT 5kΩ–0 POT
Pedal up: 0 – 50 4500 – 5500
Pedal down: 4500 – 5500 0 – 50

3-B If these resistances are wrong, it is because the pot itself is faulty,
the wires to the pot are broken, or the pedal and its linkage are not
moving the potbox lever through its proper travel. Actuate the pedal
and verify that the potbox lever moves from contacting the pedal-up
30 Curtis 1204/1205 Manual, Rev. C
5 — TROUBLESHOOTING & BENCH TESTING
stop to nearly contacting the pedal-down stop. If the mechanical
operation looks okay, replace the potbox.

3-C While you have the potbox wires off the controller, use an ohmmeter
to check for shorts between these wires and the vehicle frame. You
should see a resistance of at least 1 megohm. If it is lower than that,
inspect the wiring for damaged insulation or contact with acid. If
necessary, replace the potbox.

3-D Push the wires back on the controller terminals. It doesn’t matter
which wire goes on which terminal.

3-E Inspect the terminal area of the controller closely. Occasionally a
buildup of dirt or acid residue of a conductive nature causes electrical
leakage between the throttle input terminals and the B- or
M- terminals, leading to faulty controller operation. To check for
this problem, measure the voltage at the appropriate throttle input
terminal (upper for 0–5kΩ pots, lower for 5kΩ–0 pots), by connecting
the voltmeter (-) lead to the controller’s B- terminal. The
keyswitch must be on and a direction selected for this test.
ACCELERATOR INPUT VOLTAGE (in volts)
STANDARD
0–5kΩ POT 5kΩ–0 POT
UPPER TERMINAL LOWER TERMINAL
Pedal up: 3.8 4.3
Pedal down: 9.5 10.2
Compare your readings with these; if they are different by more
than a few tenths of a volt, contamination is probably the cause.

3-F Carefully clean off the terminal area of the controller with a cotton
swab or clean rag moistened with water, and dry thoroughly.
Be sure to turn everything off
before cleaning.
Now test the controller to see if proper operation is restored. If so,
take steps to prevent this from happening again: dirt and water
must be kept from reaching the terminal area of the controller. If
the voltages are still out of range, the controller is at fault and should
be replaced.

[jeremykent]

That is good stuff. Thank you, I will try to get on this tonight

[Storm S]

Originally Posted by jeremykent

That is good stuff. Thank you, I will try to get on this tonight

No worries. Just trying to pass along the help I got from this site. Let me know what turns out.

[jeremykent]

Test 3-A easy enough, I pulled the yellow and green wire and hooked up the ohm meter. Pedal up and pedal down readings were off. As I moved the pedal the readings just went crazy. Even holding the pedal half way down and not moving the resistance jumped all over the place. Looks like the MCOR is definitely bad mo money mo money!

[Storm S]

Originally Posted by jeremykent

Test 3-A easy enough, I pulled the yellow and green wire and hooked up the ohm meter. Pedal up and pedal down readings were off. As I moved the pedal the readings just went crazy. Even holding the pedal half way down and not moving the resistance jumped all over the place. Looks like the MCOR is definitely bad mo money mo money!

Try taking it out and giving it a good cleaning. Possibly the contacts are dirty. It honestly could be simple as that. Glad I was able to help, sorry it was not something simpler.....

[Golfdog]

Originally Posted by jeremykent

Test 3-A easy enough, I pulled the yellow and green wire and hooked up the ohm meter. Pedal up and pedal down readings were off. As I moved the pedal the readings just went crazy. Even holding the pedal half way down and not moving the resistance jumped all over the place. Looks like the MCOR is definitely bad mo money mo money!

Before forking out more money on a MCOR try do the test with an analog meter, digital meters tend to be a bit jumpy on rotary pots. Also I have the same Controller NPX 4844 and had a problem with the cart sometimes not going when the pedal was pressed. It was an intermittent issue and I believe Alltrax have or had a problem with Club Cars activating the HPD (high pedal disable) function in the controller. The solution was to return the controller and they would disable that function. I have managed to overcome the problem by splicing in a wire onto the blue wire from the key switch before the 2 pin connector to the MCOR microswitch and connecting it directly to the controller #1 spade connector, disconnecting the existing red wire on that spade that comes from the solenoid + small post. It means that when the key is turned on the controller remains powered up and the pedal activates the solenoid but it comes in second and does not activate the HPD. This may not be an issue with you but you cud try it if it is

[jeremykent]

Ok went to Walmart got a high dollar(10.00) analog meter. Readings were not good at all. Picked up a new MCOR, long story short the cart works great now. If you have to install one of the new conversion kits make sure the pin goes in the plug, they seem to move pretty easily...