Workhorse 1000E controller question.

Johnny Railey · 02-28-2019, 08:39 PM

I have workhorse 1000E with 36 volt system. Unit was originally a 4 tab speed controller but has been changed to 350 amp 3 tab controller. A2 has been deleted. Can not find service manual on 3 tab controller for troubleshooting. Unit has had f/r switch replaced and new speed controller but still won’t run. Need service info. Thanks

couch702 · 02-28-2019, 08:41 PM

Did you check the reed switch?

Sent from my SM-N950U using Tapatalk

Johnny Railey · 03-01-2019, 08:43 AM

Reed switch has been deleted. Unit was running and then needed battery batteries and tires. Replaced battery and tires and will not run. Thanks

yurtle · 03-01-2019, 08:53 AM

I used to have a gasser Workhorse and loved it.

Based on description of 4 post to 3 post controller, I'm assuming this is a series cart? Have you downloaded a wiring diagram from the stickies? Does the solenoid click?

With series carts, there are basically two circuits, one is a low current (amps) circuit that essentially makes the solenoid click. The other is a high current circuit that makes the motor go.

If the solenoid doesn't click, you'll have to follow the circuit through several switches until you find a bad switch, wire or connector. Switches include reed switch, key switch, two microswitches on the FNR and one microswitch in the throttle box.

If the solenoid does click, your circuit consists of batteries, controller, FNR switch, solenoid, motor, and all interconnecting cables/cable ends.

yurtle · 03-01-2019, 08:59 AM

For troubleshooting purposes, the forth post can be ignored. Small wires make the solenoid click, and large cables make the motor go. Since all you did was change batteries, to problem is either the battery cables or a few wires that may have gotten disturbed, and not likely a switch decided to just die, but it is possible.

As a quick check, and something that often goes bad after it's disturbed, eliminate the Molex connector, on the four wire cable from the throttle box to the wiring harness. You can try a quick check of unplugging/cleaning/replugging repeatedly several times. Dirty/corroded contacts here can cause solenoid to not click - one or two bad wires to pedal microswitch - or not go with solenoid click - one or two bad wires to ITS.

Connector usually found between controller and FNR.

Johnny Railey · 03-01-2019, 09:55 AM

Thanks for reply. Owner of cart had downloaded 28838-g01 service manual. Used it per troubleshooting guide. Solenoid good, direction switch and have checked throttle. All good guide said bad speed controller. Ordered reman 350amp per part number on old one. Still on travel and troubleshooting guide leads back to controller. I thought it might be a different troubleshooting guide for a 3 tab. It is a series controller system. I’m new to forums but was recommended by a service tech at local EZGO dealer. Thanks

yurtle · 03-01-2019, 10:18 AM

What make and model controller do you have?

yurtle · 03-01-2019, 10:21 AM

I know I attached this but it didn't take. This is the connector I mentioned above.

Johnny Railey · 03-01-2019, 10:27 AM

Part number is ez25864-g03r. FSIP reman motor controller. Model 1206-03. 36vdc. 300amp. Label says Curtis authorized service.

Johnny Railey · 03-01-2019, 10:35 AM

Don’t see a connector like that. What is it wired to?

02-28-2019, 08:39 PM	#1
Johnny Railey Not Yet Wild Join Date: Feb 2019 Posts: 7	Workhorse 1000E controller question. I have workhorse 1000E with 36 volt system. Unit was originally a 4 tab speed controller but has been changed to 350 amp 3 tab controller. A2 has been deleted. Can not find service manual on 3 tab controller for troubleshooting. Unit has had f/r switch replaced and new speed controller but still won’t run. Need service info. Thanks
Johnny Railey Not Yet Wild Join Date: Feb 2019 Posts: 7

02-28-2019, 08:41 PM	#2
couch702 Not Yet Wild Join Date: Feb 2019 Posts: 33	Re: Workhorse 1000E controller question. Did you check the reed switch? Sent from my SM-N950U using Tapatalk
couch702 Not Yet Wild Join Date: Feb 2019 Posts: 33

03-01-2019, 08:43 AM	#3
Johnny Railey Not Yet Wild Join Date: Feb 2019 Posts: 7	Re: Workhorse 1000E controller question. Reed switch has been deleted. Unit was running and then needed battery batteries and tires. Replaced battery and tires and will not run. Thanks
Johnny Railey Not Yet Wild Join Date: Feb 2019 Posts: 7

03-01-2019, 08:53 AM	#4
yurtle Gone Mad Join Date: Oct 2009 Location: Buford, GA Posts: 8,988	Re: Workhorse 1000E controller question. I used to have a gasser Workhorse and loved it. Based on description of 4 post to 3 post controller, I'm assuming this is a series cart? Have you downloaded a wiring diagram from the stickies? Does the solenoid click? With series carts, there are basically two circuits, one is a low current (amps) circuit that essentially makes the solenoid click. The other is a high current circuit that makes the motor go. If the solenoid doesn't click, you'll have to follow the circuit through several switches until you find a bad switch, wire or connector. Switches include reed switch, key switch, two microswitches on the FNR and one microswitch in the throttle box. If the solenoid does click, your circuit consists of batteries, controller, FNR switch, solenoid, motor, and all interconnecting cables/cable ends.

03-01-2019, 08:59 AM	#5
yurtle Gone Mad Join Date: Oct 2009 Location: Buford, GA Posts: 8,988	Re: Workhorse 1000E controller question. For troubleshooting purposes, the forth post can be ignored. Small wires make the solenoid click, and large cables make the motor go. Since all you did was change batteries, to problem is either the battery cables or a few wires that may have gotten disturbed, and not likely a switch decided to just die, but it is possible. As a quick check, and something that often goes bad after it's disturbed, eliminate the Molex connector, on the four wire cable from the throttle box to the wiring harness. You can try a quick check of unplugging/cleaning/replugging repeatedly several times. Dirty/corroded contacts here can cause solenoid to not click - one or two bad wires to pedal microswitch - or not go with solenoid click - one or two bad wires to ITS. Connector usually found between controller and FNR.

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03-01-2019, 09:55 AM	#6
Johnny Railey Not Yet Wild Join Date: Feb 2019 Posts: 7	Re: Workhorse 1000E controller question. Thanks for reply. Owner of cart had downloaded 28838-g01 service manual. Used it per troubleshooting guide. Solenoid good, direction switch and have checked throttle. All good guide said bad speed controller. Ordered reman 350amp per part number on old one. Still on travel and troubleshooting guide leads back to controller. I thought it might be a different troubleshooting guide for a 3 tab. It is a series controller system. I’m new to forums but was recommended by a service tech at local EZGO dealer. Thanks
Johnny Railey Not Yet Wild Join Date: Feb 2019 Posts: 7

03-01-2019, 10:18 AM	#7
yurtle Gone Mad Join Date: Oct 2009 Location: Buford, GA Posts: 8,988	Re: Workhorse 1000E controller question. What make and model controller do you have?

03-01-2019, 10:27 AM	#9
Johnny Railey Not Yet Wild Join Date: Feb 2019 Posts: 7	Re: Workhorse 1000E controller question. Part number is ez25864-g03r. FSIP reman motor controller. Model 1206-03. 36vdc. 300amp. Label says Curtis authorized service.
Johnny Railey Not Yet Wild Join Date: Feb 2019 Posts: 7

03-01-2019, 10:35 AM	#10
Johnny Railey Not Yet Wild Join Date: Feb 2019 Posts: 7	Re: Workhorse 1000E controller question. Don’t see a connector like that. What is it wired to?
Johnny Railey Not Yet Wild Join Date: Feb 2019 Posts: 7

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