How to test controller

[Jefft247]

My cart was working fine and went back to it about two days later and it will not move. I spoke to the previous owner and he said the cart did the samething so he had to replace the controller. He said the controller that was installer came out of a junk yard. My question is how can I test the controller? Good batteries and a new sileniod. The cart serial number is A9947-827211. Thanks

[jjance]

Replace with known good or eliminate everything else as being a problem. Or maybe depending on what type it is you could send it back to the manufacturer for inspection/repair.

[scottyb]

Series Controller test
Connect your voltmeter between the main negative terminal on the battery pack an the M- terminal on the controller.

Push pedal just far enough for the solenoid to click.
You should read Full battery pack voltage.
If you don't have it, troubleshoot the red and blue cables and their connection and the contacts and components associated with them.

If you do have full battery pack voltage, slowly push the pedal to the floor.
The voltage should smoothly decrease to Zero, or close to Zero.

If it doesn't, check the throttle input to the controller.

If it does, and the motor isn't turning, you should see smoke or something ought to be getting mighty hot.

If the voltage was measured between the controller's M- and B+ terminals, then you are measuring across the motor and the voltage would be Zero with pedal up and full battery pack voltage with pedal down.

[mrgolf]

I ran across a cart a few months ago that did that. Turned out to be a tow run switch. They get old and don't make good contact. Try turning it on off a few times or jump the two wires.

Never mind. Just realized it don't have tow run switch. Oops.

[Jefft247]

While checking my controller I have noticed I only have 34 volts on the internal controller compactor. When I push the pedal my meter then goes up to 50 volts.but still no movement

[scottyb]

Originally Posted by Jefft247

While checking my controller I have noticed I only have 34 volts on the internal controller compactor. When I push the pedal my meter then goes up to 50 volts.but still no movement

If the controller is passing current and the cart is not moving the trouble is with the delivery system or the motor. The motor can be tested for unwanted continuity to see if it has shorted out. Each cable end is a potential problem, check them all with a pull + twist test. The F&R switch is suspect in a series drive cart. Failed contact in the F&R is common and will stop the cart.

More troubleshooting info here http://www.cartsunlimited.net/

[smokey tennis shoe]

Originally Posted by scottyb

Series Controller test
Connect your voltmeter between the main negative terminal on the battery pack an the M- terminal on the controller.

Push pedal just far enough for the solenoid to click.
You should read Full battery pack voltage
If you don't have it, troubleshoot the red and blue cables and their connection and the contacts and components associated with them.

If you do have full battery pack voltage, slowly push the pedal to the floor.
The voltage should smoothly decrease to Zero, or close to Zero.

If it doesn't, check the throttle input to the controller.

If it does, and the motor isn't turning, you should see smoke or something ought to be getting mighty hot.

If the voltage was measured between the controller's M- and B+ terminals, then you are measuring across the motor and the voltage would be Zero with pedal up and full battery pack voltage with pedal down.

Can someone explain which red and blue wires he is talking about here? I see more than 1 blue and more than 1 red wire on my cart. More specific, whichever blue and red wires, where are they going to or from?

[Jefft247]

I just found the problem. One of the studs on my motor is loose. Is there anyway to tighten these? And can I use a regen 2 motor on this cart? I have two of them.

[mrgolf]

I think you have a series drive system. No they are complete different motors.

[Jefft247]

Ok thanks everyone. The wire is broken off the stud.