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Old 08-20-2012, 10:45 PM   #1
Whiskey11
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Default I think I need a new controller???

The cart took a dump on our last trip. The reverse has been suspect for a while now, working now and then not working then working again. Now nothing is working!!! I just checked the thing out and it seems power is getting to the controller but there is nothing coming outa the controller. The motor is getting nom power. I assume I need a new controller. Are there any suggestions on a replacement controller? The cart is lifted 4 seated with 20x11x10 tires. Everything else is stock. Thx for the help....
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Old 08-21-2012, 08:33 AM   #2
JohnnieB
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Default Re: I think I need a new controller???

If that is a series cart, the F/R switch is a more likely suspect if it worked okay forward and occasionally misbehaved in reverse.

Personally, I would prove the controller was bad before I started poking and hoping.
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Old 08-21-2012, 08:51 AM   #3
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Default Re: I think I need a new controller???

If it is a PDS or DCS drive cart your assumption is correct based upon statistics.

Intermittent operation in one direction is a common failure symptom, which never clears up and goes away. Just like your cart, one time they just quit all together.

Running those big tires on a stock controller will eventually kill the control. Now is a good time for an upgrade.
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Old 08-21-2012, 12:07 PM   #4
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Default Re: I think I need a new controller???

Quote:
Originally Posted by scottyb View Post
If it is a PDS or DCS drive cart your assumption is correct based upon statistics.

Intermittent operation in one direction is a common failure symptom, which never clears up and goes away. Just like your cart, one time they just quit all together.

Running those big tires on a stock controller will eventually kill the control. Now is a good time for an upgrade.
Im lost when it comes to these carts, PDS or DCS, I know its a series cart and im just guessing its a 97. checking volts at diferent locations it seems that the controller is where power is being lost. There is voltage getting to the controller but nothing coming out of it to the motor.
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Old 08-21-2012, 12:20 PM   #5
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Default Re: I think I need a new controller???

Here is the drive system identification chart.
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File Type: jpg ezgo-guide-#2.jpg (144.6 KB, 0 views)
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Old 08-21-2012, 03:59 PM   #6
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Default Re: I think I need a new controller???

Quote:
Originally Posted by Whiskey11 View Post
Im lost when it comes to these carts, PDS or DCS, I know its a series cart and im just guessing its a 97. checking volts at diferent locations it seems that the controller is where power is being lost. There is voltage getting to the controller but nothing coming out of it to the motor.
Measure battery pack voltage.
Should be about 38.2 if fully charged.

Then connect DVM between B- and M- terminals on controller.
Key = ON
F/R = F or R
Slowly press throttle until solenoid first clicks.
You should read full battery pack voltage.

If not, you've got an open cable, contact or connector in the high current loop.
My guess would be the F/R switch contacts.

If you do get full battery pack voltage.
Press throttle slowly to floor.
The voltage should decrease down to nearly zero as pedal is depressed.

If not, check for B+ at Pin-4
If you've got B+ at Pin-4, check ITS.

If ITS is good, controller is bad.

--------------
Like Scotty said earlier, those big tires will kill a stock controller, so if it is bad, replace it with something that can deliver the needed amps without a melt-down.
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Old 08-21-2012, 05:08 PM   #7
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Default Re: I think I need a new controller???

Place buggy on jack stands to simplify this procedure.
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Old 08-21-2012, 05:09 PM   #8
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Default Re: I think I need a new controller???

If you don't have jack stands, now would be a good time to buy some. You're gonna need 'em.
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Old 08-23-2012, 11:38 AM   #9
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Default

Quote:
Originally Posted by scottyb View Post
Here is the drive system identification chart.
Thx ScottyB!!! Can't wait to get new parts!!


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Old 08-23-2012, 12:53 PM   #10
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Default Re: I think I need a new controller???

The new HD F&R is on it's way
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