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Discussion Starter · #1 ·
When in forward positing: Machine is very weak until the pedal is press all the way down
When in reverse: Machine is strong from start to finish.

Adjusting the pedal only changes the power in the forward position when all the way pressed to the floor.

Is there an adjustment that i can make somewhere else to increase the forward power.

Can i change the brushes in the electric motor to correct the problem or is this even possible (2 part questions)?

thank you
 

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What does the status lights indicate?

The speed sensor circuit has the provision for reduced vehicle speed if the sensor is not detected by the controller. The travel speed of the vehicle will be reduced to a few miles per hour and continue at this slow speed until the speed sensor input is restored.
 

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Discussion Starter · #3 ·
Status light on the controller under the seat?

Forward : When the peddle is fully pressed it's at full power.

Could the forward and reverse be back words. so Question: on a normal machine when pressing reverse does it start slow for safety reasons?

I had issues with the wiring in general where the machine would only go forward.
 

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FORWARD & THROTTLE CIRCUIT OPERATION
Function:
To cause the vehicle to be propelled in a forward direction under the control of the operator.
Operating Conditions:
To operate the vehicle in forward, the drive/service switch must be in the DRIVE position, the key switch must be ON, the park brake must be OFF, the directional control in the FORWARD (pushed down) position, the throttle pedal PRESSED slowly and smoothly to the desired speed, and the area for the vehicle to be operated must be clear of bystanders.
System Operation:
The input signal power for the forward command is supplied through the S2 drive/service switch and the S3 key switch. See “SECONDARY SWITCHED POWER CIRCUIT OPERATION” on page 30.
When performing a forward command, several switches are activated at the same time. The S4 throttle switch, S5 park brake switch, and the S8 forward switch will all have their contacts closed to supply 48VDC input power to the A1 motor controller. The R1 throttle potentiometer will also be activated to supply an input to the A1 motor controller to signal the motor controller as to how far the throttle pedal has been pressed down (how fast the operator is attempting to travel).
For all of these inputs there are several outputs performed by the A1 motor controller that must happen for the vehicle to operate in forward. The J1-17 terminal must switch to battery negative causing the K1 motor relay to pull in completing the path from the battery positive (B+) terminal to the motor controller (B+) terminal and the M1 drive motor A1 terminal. The F1 terminal of the motor controller must supply output voltage to the motor field windings while the F2 terminal will become the battery negative path for the field winding. The motor controller as a result of the position of the R1 throttle potentiometer, will change the output on the M1 terminal causing the motor to run faster.
If any one or more of these inputs or outputs is not correct, the A1 motor controller will shut down and not allow the vehicle to respond to the forward command.
When performing a forward command 48 volt power is supplied from the S3 key switch to the 382, 372, 362, 322, 332, 342, 312, 302 and 102 Red wires.
With the park brake in the OFF position, the 322 Red wire supplies power to the S5 park brake switch contacts (normally open), 269 Tan wire and the A1 motor controller J1-21 terminal. The A1 motor controller reads the input of full battery voltage on the J1-21 terminal and will power the motor controller to allow output on either the F1 (forward) or F2 (reverse) terminals.
With the directional lever in the forward position, power is supplied from the 332 Red wire to the S8 forward switch contacts (normally open), 222 Pnk wire and the A1 motor controller J1-10 terminal. The A1 motor controller will respond with the F1 terminal having a positive voltage output to the 640 Blk wire, M1 drive motor E1 terminal, through the field windings to the E2 terminal, 659 Wht wire and back to the A1 motor controller F2 terminal which is the battery negative path for the forward function.
When the throttle pedal is pressed the 372 Red wire supplies power to the S4 throttle switch contacts (normally open), 125 Grn wire to the A1 motor controller J1-8 terminal. The A1 motor controller will respond with the J1-17 terminal being switched to battery negative. As a result of this input the A1 motor controller will switch the J1-17 terminal to battery negative. This will then provide a battery negative path for the 264, 404 and 414 Yel/Blk wires, K1 motor relay, and P1 hour meter/battery fuel gauge (optional). This will energize the K1 motor relay closing the relay contacts supplying battery voltage to the 600 Blk wire and the B+ terminal of the motor controller and the A1 terminal of the drive motor. This will also provide the battery negative for the hour meter and begin recording the time that the K1 motor relay is energized.
The R1 throttle potentiometer receives 4.5 volts from the motor controller when the primary switch circuits are activated. The J1-13 terminal of the A1 motor controller supplies approximately 4.5 volts to the 244 Yel wire and the R1 throttle potentiometer. With the R1 throttle potentiometer in the neutral position the resistance of the throttle potentiometer drops the voltage to the 256 Blu and 251 Brn wires to between 0.3 - 0.6 volts. As the throttle pedal is pressed down, the voltage on the 256 Blu wire will raise to 4.0 volts when the pedal is pressed all the way down. If the pedal is only pressed half way down, throttle pot rotated 50%, the voltage on the 256 Blu wire will be approximately 50% or about 2- 2.2 volts. The 251 Brn wire will stay at approximately 0.4 volts. As a result of the throttle pedal being pressed down and changing the voltage on the 256 Blu wire the A1 motor controller will change the voltage of the M- terminal. When the throttle pedal is pressed down to the point that it just activates the S4 throttle switch, the voltage on the M- terminal will be approximately 48 volts. As the pedal is pressed further down, the M- terminal voltage will decrease to approximately 24 volts when the pedal has reached full travel. This then allows the drive motor to run at full rpm, and full speed drive.
 
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