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Unread 06-21-2008, 11:05 AM   #1
Not Yet Wild
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Default 1989-1991 Club Car Controller

A buddy has a 1989 to 1991 Club Car that has a fried controller. So instead of spending the money to fix it he is going to give it to me. Not knowing anything about a cart I need some help.

When he got it all the 6V batteries were bad. So he put 3 car batteries in instead of the 6 6v batteries. He ran it that way for 5 to 6 years this way. Is this okay to do? Any problems with this type setup?

The major problem is the controller. It looks like it caught on fire. Melted the plastic and the board. I am going to buy another controller but before spending $300-$500 dollars I want to make sure nothing else is wrong. Can anything else cause the controller to fry? Or was it just time for it to go? Also does anyone have a wiring diagram for this model? Any pre check items before installing the new controller so I wont fry the new one?

Thanks any info would be greatly appreciated!
Robert
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Unread 06-21-2008, 11:38 AM   #2
nimda
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Default Re: 1989-1991 Club Car Controller

It's better to use standard golf cart batteries for several reasons. 12 volt automotive batteries won't give you a very good runtime. They will "work" but their life span is not as good as a cart battery. I guess it mainly depends on how much your going to use it. If it were me.....I would read, read and read some more...and when you feel comfortable enough to tackle the project read some more. More than likely the controller fire was caused by something being mis-wired. As long as it's wired right there's nothing to worry about.

Theres no reason you can't fix it so go ahead and buy a good after market controller. An Alltrax will do fine. Kelly controllers, Logisystmes and a few others make decent controllers a little cheaper than an Alltrax. Grab yourself a wiring diagram and look over the cart and make sure its all wired right.....or just re-wire the whole cart. That may be a better option for you....that way you don't have to worry about someone else's mistakes. If they used 3 12 volt batts that generally means they didn't wanna spend the cash to do it right so theres no telling what is wrong.


As long as those 12 volt batteries are good you can use them to get it re-wired and running , then swap the 12 volt automotive batteries to golf cart batteries.
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Unread 06-21-2008, 02:00 PM   #3
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Default Re: 1989-1991 Club Car Controller

Welcome to the forum rkersh409...................
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Unread 06-21-2008, 02:08 PM   #4
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Default Re: 1989-1991 Club Car Controller

I don't think it was a wiring problem. He was using it when he pushed the peddle to go and heard a pop.

The sn# is A9143 268079 can someone point me in the direction to find the year, and a wiring diagram?

Thanks again!
Robert
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Unread 06-21-2008, 02:11 PM   #5
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Default Re: 1989-1991 Club Car Controller

It's a 1991......... the 91 just after the A...............
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Unread 06-21-2008, 05:23 PM   #6
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Default Re: 1989-1991 Club Car Controller

Thanks guys! Have one other question. Do you know what controller I need? The model number is melted and I cannot read it. The only thing I can make out is Curtis. Its a 1991 36V Series wound motor. The motor model number is 5BC48JB764. I have no idea what amperage I need. Also what else do I need to know before ordering a controller?
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Unread 06-25-2008, 11:45 PM   #7
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Default Re: 1989-1991 Club Car Controller

The stock controller is probably a Curtis #1204-015 , 275 amp
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Unread 06-27-2008, 01:52 AM   #8
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Default Re: 1989-1991 Club Car Controller

Did you get the wiring diagram you were looking for? Look at the sticky in the top of this forum group and you will find what you need.
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Unread 06-27-2008, 09:58 AM   #9
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Default Re: 1989-1991 Club Car Controller

Yes thanks guys I found what I was looking for. Does anyone else have a bigger pic of the wiring diagram? My eyes isnt that good .

Does any one know if the Kelly Controllers are new or rebuilt?

Thanks,
Robert
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Unread 06-27-2008, 10:13 AM   #10
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Default Re: 1989-1991 Club Car Controller

Quote:
Originally Posted by rkersh409 View Post
Does anyone else have a bigger pic of the wiring diagram? My eyes isnt that good .
I copied the pic and pasted it into Word and it blew up just fine.
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