95' Club Car Potentiometer Problem

[Sergio]

Disconnect the green wire from the controller and measure the voltage right at the terminal #2, if you still get 0V, the controller is bad.

[jjance]

I don't think I'd start by jumping headlong into the wiring like that on any job. Most all (like 95%) of the time I see a Precedent in for repair, it's either for batteries on an MCOR. Rarely ever is there anything else wrong that isn't directly related to a customer blowing it up. Stagg99.

I was going to post this yesterday. Today it seems more in line.

[myardley]

Originally Posted by Sergio

Disconnect the green wire from the controller and measure the voltage right at the terminal #2, if you still get 0V, the controller is bad.

Removed green wire, check voltage right at terminal 2 - reads 0.01v..

That mean its no Bueno ?

[myardley]

Originally Posted by jjance

I was going to post this yesterday. Today it seems more in line.

I did wire the batteries backwards a while back before i swapped to MCOR4... Some smoke came from somewhere i think the controller, you think that it means the controller is a goner?

[myardley]

Originally Posted by jjance

I was going to post this yesterday. Today it seems more in line.

Batteries on the MCOR? how do i check that

[CCFanatic]

Originally Posted by myardley

I did wire the batteries backwards a while back before i swapped to MCOR4... Some smoke came from somewhere i think the controller, you think that it means the controller is a goner?

That is most likely your problem

[myardley]

UPDATE:

Okay got a rebuilt controller (same model) - Everything is hooked up per the wiring diagram, and nothing still. Solenoid clicks, but no movement.

Prior to getting the new controller my terminals read:

Terminal 1(red) ----- (49v) pedal pressed
Terminal 2(green) --- (0v) pedal pressed
Terminal 3 (yellow) --- (0v) pedal pressed

NOW the new controller reads:

Terminal 1(red) ---- (0.3v) pedal pressed
Terminal 2(green) ---- (9-10v) pedal pressed
Terminal 3(yellow) ---- (0v) pedal pressed


Not sure where to go now now.. Any ideas??

[Sergio]

Originally Posted by myardley

UPDATE:

Okay got a rebuilt controller (same model) - Everything is hooked up per the wiring diagram, and nothing still. Solenoid clicks, but no movement.

Prior to getting the new controller my terminals read:

Terminal 1(red) ----- (49v) pedal pressed
Terminal 2(green) --- (0v) pedal pressed
Terminal 3 (yellow) --- (0v) pedal pressed

NOW the new controller reads:

Terminal 1(red) ---- (0.3v) pedal pressed
Terminal 2(green) ---- (9-10v) pedal pressed
Terminal 3(yellow) ---- (0v) pedal pressed


Not sure where to go now now.. Any ideas??

Both of those measurements are OFF.

Your Terminal #2 (green) reading is only possible if the MCOR is not plugged (no load).

The Terminal #1 (red) gets power with the Solenoid, so if the solenoid is clicking, make sure the wire between the solenoid small positive post and controller Terminal #1 is good.

The Terminal #2 voltage being that high can be an indication the Micro-Switch #3 in the FNR or the wiring to the switch is bad, or that Your MCOR is disconnected.

You can disconnected the MCOR and measure the voltage from the black wire at the MCOR to pack negative. You should see the same voltage as in Terminal #2 when the FNR is in forward.

[myardley]

Sergio,

Thanks for the info, Im gonna re-check the connections you mentioned. I will re-post once I get that done. Really hoping to get this thing up and running soon.

[myardley]

UPDATE:

Okay, checked all the wiring from the solenoid to terminal 1(red) - everything good. Sergio you mentioned that the MCOR might be unplugged if it was causing that 9-10v reading on terminal 2 (green). You were correct.

I was looking at the connection between the MCOR harness and the cart harness and it wasn't really "connected." Turns out I needed to use that piggyback cable. My original harness was not compatible with the new MCOR harness, without using that piggyback adapter thing. Well I had to do some digging to find it. I found it and hooked it up and what do you know, she runs.

I did need the new controller despite that problem with the connection on the harness, so once I got the controller and made sure the harness was actually connected correctly, BOOM, everything good.

Sergio, thanks a lot for your help in all this madness.