99 DS, one speed, All Out!!!!!

[Sergio]

I think the issue is a bad connection on the negative side (Purple wire).

Those old cart/controller setups had some poor safety engineering designs.

I remember helping someone with the old 36v controller with a 0-5kΩ throttle and much to my surprise if the throttle wires were disconnect the cart ran at full speed

In Your system if the negative is missing, the controller will always see +5v on the yellow wire and go full speed in forward or reverse.

The newer designs not only have a "High Pedal" detect system that will not start if the throttle is more than 25% applied, but it also has resistors built in the harness so the controller can detect a short and/or disconnected throttle wire.

[TahoeDawgZ71]

Sergio you are the man

[kimrpaige]

OK, Here we go again!! Just when I thought all is/was good. It is doing it again. I did all again, pulled yellow and green off, no run. ohmed yellow and green and poteniometer is working with gas pedal 0-5700 Ohms. ohmed out whit/black with purple at V_Glide connector and 5700 Ohms. Put it all bsck together and still full bore. So you guys still think it is the purple ground wire. If so I will remove the V-Glide and have a look inside. Thanks again, Kim

[Sergio]

Instead of measuring resistance, go ahead and measure the voltage since that is how the controller throttle works anyway.

Turn key ON and FNR in Forward.

Just unplug the Yellow wire from controller Terminal #3.

Set Your meter to 20v DC and measure the voltage from the Yellow wire (positive probe) to controller B- (negative probe).

The voltage should vary from approximately 0-5v from pedal Up to pedal Down.

[kimrpaige]

OK, quick question. Do I need to unplug the green wire also as when I just remove the yellow from terminal 3, turn the key on and in fwd, then hit the gas the cart moves. Also I am measuring from the yellow wire to B- correct and not from the lug on the controller marked 3 to B-. If it suppose to move with only the yellow wire off then I will need to jack the rear axle off the ground. Kim

[Sergio]

You should have:

Terminal #1 Red wire
Terminal #2 Green wire
Terminal #3 Yellow wire

The only wire that needs to be disconnected is the Yellow from terminal #3, and yes, you measure the voltage on the wire itself.

Make sure that is how the wires are connected as the cart should not have moved without a wire on terminal #3.

Sorry, forgot, you should always lift one rear wheel off the ground for safety.

Also, only allow the motor to run long enough to take a voltage reading.

[kimrpaige]

Sergio,
Yes the wires are connected correctly 1 red, 2 green, and 3 yellow. And yes the cart does move/lunge forward with the yellow wire off the controller. I have the front wheels off the cart now and having tires mounted so later when I get them back on, I will jack the rear axle up and take measurements. Kim

[Sergio]

I just remembered You can also just unplug the OBC and that will prevent the solenoid from engaging so you can take the voltage reading without the motor running.

[kimrpaige]

Back again, I disconnected the OBC, read voltage at the yellow wire, I got 0V at idle and it gradualy went up to 7.6V at full throttle. Kim

[Sergio]

Well, David (TahoeDawgZ71) was right all along, your controller is bad.

If the yellow wire starts at 0v, that should have effectively prevented the controller from sending any voltage to the motor.

Just call David on the phone (number on his signature) and talk about options for controllers.