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Unread 07-05-2008, 10:21 PM   #1
Not Yet Wild
 
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Default Controller upgrade problem

I bought a very clean, low mileage 1995 E-Z Go (non DCS) 36v Series cart. I installed a high speed motor, #4 cable and a new battery pack. Of course the speed increased but the torque went away. On hot days here in Arizona, the cart will come to a stop when climbing any rather steep grade - continue on only when the controller cools a bit. So, I ordered an upgraded, rebuilt controller from 'Controller Test Services' in California. The unit arrived in a timely manner, good price and looks good. They built me a 550 amp, 36/48v unit in a larger 1204 case to replace the stock 1206 E-Z Go controller.

As I started installing it, I found a problem that I can't resolve. The stock controller has four lugs, the new unit has only three. The A2 terminal is missing! First thought was that they sent the wrong unit. But, as I looked at the upgrade controllers offered by internet sellers, (Alltrax, Curtis etc.) they also seem to be missing A2. Does anyone have experience to share on this?
Thanks
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Unread 07-05-2008, 10:30 PM   #2
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Default Re: Controller upgrade problem

I have heard of this before. You don't need the A2 terminal. Just follow wiring diagram that should have come with controller.
Let us know how that controller works. I've looked at their web site and they have some great prices.
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Unread 07-05-2008, 10:46 PM   #3
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Default Re: Controller upgrade problem

Welcome to BGW Databoy!

On the stock unit there were 2 cables attached to the A2 terminal. Take those 2 cables and bolt them together and tape them up. The A2 is not needed. You can also run 1 single connection from the motor to the F/R switch instead of bolting the 2 together.

On units with an A2 there will be a cable running from A2 on the motor to the A2 on the controller....then there is a cable running from the F/R switch to the A2 on the controller......like I said...just bolt together, tape and go!
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Unread 07-05-2008, 10:54 PM   #4
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Default Re: Controller upgrade problem

There was no wiring diagram enclosed with the controller. The package arrived this morning. My Service Manual is of little help as it calls for an A2 hook-up. I'll try it without A2 and call CTS on Monday.
Thanks:
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Unread 07-05-2008, 10:58 PM   #5
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Default Re: Controller upgrade problem

Thanks Roady89
I should have it back on the road in the morning
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Unread 07-06-2008, 09:40 PM   #6
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Default Re: Controller upgrade problem

Thanks for the help.
The 550 amp controller from "Controller Test Services" seems to work very well. The torque has increased enough that the hills are not such a problem. The service, price and product from CTS seems very satisfactory.
The 36 volt E Z go will still not outrun my wife's Yamaha G19 with high speed (6:1) gears and #4 cable, but it is getting close. Next for the E Z go will be a 48 volt conversion and larger tires. I believe that this controller will support this.
Then, of course, I'll have to look at a 2 speed motor for the wife's Yamaha!
The golfer with the fastest cart never has a bad lie.
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Unread 07-06-2008, 09:56 PM   #7
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Default Re: Controller upgrade problem

Welcome to the forum databoy................
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Unread 07-06-2008, 11:48 PM   #8
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Default Re: Controller upgrade problem

Quote:
Originally Posted by databoy View Post
Thanks for the help.
The 550 amp controller from "Controller Test Services" seems to work very well. The torque has increased enough that the hills are not such a problem. The service, price and product from CTS seems very satisfactory.
The 36 volt E Z go will still not outrun my wife's Yamaha G19 with high speed (6:1) gears and #4 cable, but it is getting close. Next for the E Z go will be a 48 volt conversion and larger tires. I believe that this controller will support this.
Then, of course, I'll have to look at a 2 speed motor for the wife's Yamaha!
The golfer with the fastest cart never has a bad lie.
Controllers are voltage specific, so be certain your controller is made for 36 to 48 volts before you try it!
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