workhorse 1000e build/repair

[Krylok]

New to electric golf carts so this is all new to me but I do have a background in automotive, but I don't think that matters lol.

So I'm starting a build thread to help people find a starting point and get ideas. I'm a member of some other forums and it helps a ton to see someone build something from start to finish and see the progress along the way.

Got a 1999 ezgo workhorse 1000e from a local guy. He said he got it as a project but never touched it. Told me the previous owner put 3 12volt batteries in it and couldn't get it to work after that. To get it on the trailer he used a jumper cable connected from the battery to the controller (for about 90 seconds). It worked but the jumper cable was a bit hot after that. Once I got home I tried the same trick to no prevail.

I noticed the dioed and the resistor on the solenoid where burnt, wires melted on both.
One of the nuts on the solenoid was welded onto the terminal from overheating. Parts on order.

I'm going to check and clean all of the connections, trace all wires to make sure they're properly ran and order a new charger because the one he gave me doesn't work (fried dioed on the board). I have also charged each battery and they look great.

I'm only going to use this for yard work, granted it's more of a farm then a yard so I don't know if I'm going to change back to a 6-6v battery pack or keep it a 3-12v but it will be after it's running well first.
Pictures incoming.

[Krylok]

Here it is. What a beautiful cart. Lol
You can see the solenoid in bad shape.

[Krylok]

And the charger. Not sure if it's repairable.

[kgsc]

Well the diode is on backwards. Stripe should be on the red wire and resistor is toast.

[Krylok]

The controller is no good. I'm going to order one but not sure what throttle type I need. Also don't know what the high pedal disable option is. I'm looking but can't find anything about it.

[kgsc]

Throttle is an ITS. HPD basically means that the pedal must be all the way up when the controller is energized. That way if you have the pedal half way down when you turn on the key the cart doesn’t run over someone

[Krylok]

One more question, what amperage did the original controller have? I have seen anything from 275a all the way to 500a.
Should I go bigger?

[kgsc]

Yep. Bigger the better

[Krylok]

Ok. The old one had a lot of water in it, I'm sure that didn't help.
500a programed to type 6 ITS is on order.

[kgsc]

Little late but what you have is a series drive cart. If you were changing the motor as well you could go sepex and eliminate the clunky FnR switch. Would require some wiring and a fnr toggle but less parts.