1998 club car DS controller conversion to Alltrax

[scottyb]

Put the cart on jacks and remove the key, look at the throttle linkage under the cart while you press the pedal down and see if there is just that much slop in the pedal linkage before the wiper moves.

[Sergio]

The wire goes between posts #2 and #3 in the picture below:





The issue with the original design is that the wiper arm is resting on the pad that is not connected to anything, so when You turn the key switch ON and the controller does a throttle check it detects an "open throttle" and issues an HPD fault.

If You connect the post #2 and #3 together, the throttle will be at the 0 level when pedal is up and you can enable HPD.

[HaulnA$$]

Originally Posted by scottyb

Put the cart on jacks and remove the key, look at the throttle linkage under the cart while you press the pedal down and see if there is just that much slop in the pedal linkage before the wiper moves.

I did that already when I had the cart all torn apart. The wiper moves and micro switch engages within the first 5% of throttle movement. When I did my upgrade, I tore the cart down to the frame and went through everything. Cleaned up the original harness, disassembled and cleaned up the F/R switch and throttle and checked throttle resistors, adjusted brake and throttle linkages, rebuilt the front suspension. You name it and I probably did it.

[HaulnA$$]

Originally Posted by Sergio

The wire goes between posts #2 and #3 in the picture below:





The issue with the original design is that the wiper arm is resting on the pad that is not connected to anything, so when You turn the key switch ON and the controller does a throttle check it detects an "open throttle" and issues an HPD fault.

If You connect the post #2 and #3 together, the throttle will be at the 0 level when pedal is up and you can enable HPD.

Thanks, I’m gonna add the jumper and clear the auto-cal and do a throttle relearn. Hope that fixes it. With going to 48V and a 500A controller, the throttle is very touchy even after playing with the linearization settings.

[Sergio]

The 2-wire throttle also has a lower resolution.

When using the Multi-Step throttle as a 2-wire rheostat, You only have 6 distinct steps in the speed control, but as a 3-wire voltage divider, You have 10 distinct steps since an intermediate step is generated when the wiper arm bridges 2 pads (except top and bottom).

The throttle step percentages are approximately:

16%, 19%, 30%, 36%, 46%, 56%, 64%, 75%, 82%, 100%

Add the wire between post #2 and #3 .

You then just need to add a wire (#25 in the picture) to convert your throttle to a 3-wire:

Wiper Arm - Post #1 - goes to Controller J5

Low side - Post #3 (wire #24) - goes to Controller B-

High Side - Post #9 (wire #25) - goes to Controller J4

[HaulnA$$]

Originally Posted by Sergio

The 2-wire throttle also has a lower resolution.

When using the Multi-Step throttle as a 2-wire rheostat, You only have 6 distinct steps in the speed control, but as a 3-wire voltage divider, You have 10 distinct steps since an intermediate step is generated when the wiper arm bridges 2 pads (except top and bottom).

The throttle step percentages are approximately:

16%, 19%, 30%, 36%, 46%, 56%, 64%, 75%, 82%, 100%

Add the wire between post #2 and #3 .

You then just need to add a wire (#25 in the picture) to convert your throttle to a 3-wire:

Wiper Arm - Post #1 - goes to Controller J5

Low side - Post #3 (wire #24) - goes to Controller B-

High Side - Post #9 (wire #25) - goes to Controller J4

Hmm.... If I don’t like it after the jumper, I will definitely do this.

[johnnyscart]

Originally Posted by Sergio

The HPD (High Pedal Disable) is a safety feature that should normally be used (turned ON).

If You had to disabled the option, it indicates an issue with the throttle (Multi-Step Potentiometer).

At the very least You should have a wire between the posts #2 (no resistor) and #3 (the first one with a resistor) to make sure there is no chance of the Multi-Step sending an invalid throttle signal to the controller when the Pedal micro-switch closes.

While the above scenario is harmless, disabling the HPD for that issue will also allow you to turn the key switch ON with the pedal all the way down and the cart will take off at full speed.

Sergio,
are you saying to run the jumper between 2 and 3 and then re-enable HPD?