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Old 07-10-2018, 10:20 AM   #1
YamahaCRN35
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Default Sevcon controller question

I’ve got a Columbia tug cart with a Sevcon controller and it is in a 2 flash illegal start condition.
Controller part number is 633t45319
Is it just supposed to have 5 volts for the accelerator micro switch?
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Old 07-10-2018, 01:38 PM   #2
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Default Re: Sevcon controller question

The controller will have 5 volts, then goes to B- through the accelerator device. Attached is the 2 flash chart which lists multiple possibilities.
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File Type: jpg 2 Flash.JPG (76.1 KB, 0 views)
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Old 07-10-2018, 02:25 PM   #3
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Default Re: Sevcon controller question

Thanks for the quick reply.
The pb6 box is working properly at 0-5.5.
The f/r selector is working properly
And then I’m getting around 4.7v at the micro switch
The cart doesn’t flash the 2 code until after the accelerator is pressed

I just wasn’t sure if that microswitch was supposed to have 5v or the full 48

Any suggestions on what to check next?
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Old 07-10-2018, 04:12 PM   #4
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Default Re: Sevcon controller question

Rest of the potbox. Make sure the microswitch closes first then ohms from 0-5k.
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Old 07-10-2018, 05:25 PM   #5
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Default Re: Sevcon controller question

10/4. I don’t know why I didn’t think of that but I’ll check it tonight and let you know. Thanks
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Old 07-10-2018, 05:43 PM   #6
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Default Re: Sevcon controller question

Just remember to always check what the controller is seeing. The pedal switch goes to pin four of the controller and the potentiometer goes to pin 10. If a wire in the harness were broken you wouldnt know by just checking the device. For that matter the pin in the harness at the controller could be bad.
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Old 07-16-2018, 06:54 AM   #7
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Default Re: Sevcon controller question

Yeah, once everything checked out good at the devices I read everything at the harness plug. Still can’t find anything wrong with its operation. I really don’t think the controller is bad because it still has rollaway protection
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Old 07-16-2018, 08:49 AM   #8
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Default Re: Sevcon controller question

A bad controller rarely has the 2 flash. I've seen 3, 4, or 9 flash as bad controllers, but not 2.

The 2 can also be the seat switch circuit. The older cars without the seat switch had a wire loop in the harness (black). If a seat switch was added, that loop was cut and the switch hooked in series.

Pin 5 of the controller would normally go direct to B- through that black wire, so if there is any voltage present at pin 5, there is a continuity problem.
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Old 07-16-2018, 05:51 PM   #9
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Default Re: Sevcon controller question

I really appreciate all the help.
One more quick question. How are the pins numbered?
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Old 07-17-2018, 09:48 AM   #10
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Default Re: Sevcon controller question

I didn’t see the markings on the controller till I looked again but pin 5 has A negative. The only thing I can think of is to take the controller out of the cart and clean the poopoo out of the contacts in the connector. everything in the harness seems to be correct
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