No output on 488 amp. controller

[jhbluesman]

I have a 96 ez-go, lifted, stock motor, 488 amp.controller, 4 ga. cables, and a up graded f/r. switch. It is dead in the water. I can't get any voltage reading out of controller that is 16 months old. I think it needs to be replaced. Got controller from buggies unlimited. I think it is a Curtis on a 1204 footprint. I would like to get it rebuilt if possible, or do I just need to bite the bullet and get a new one? Does anyone one have any suggestions? The motor runs in forward and reverse if I bypass controller.

[rusty]

Hello jhbluesman and Welcome to the forum.

Be sure to check the systems micro switches & etc. before you bite the bullet on a new controller.

A motor will run without the full functions of the F/R switch and associated microswitches as well as the REED Switch and ITS unit if you just jumper across the controller.

As I said, there are many small items that will render your cart dead.

Check the wiring diagrams and check your system against the diagram that matches your system first. Good Luck.

[crash12888]

What is the reading on the pot box? That can cause it as well.

[BigBlockMan]

Is it a1204 controller or a 5 pin 1206 in a 1204 case. Either way we can rebuild it and raise the output if needed

[jhbluesman]

Originally Posted by rusty

Hello jhbluesman and Welcome to the forum.

Be sure to check the systems micro switches & etc. before you bite the bullet on a new controller.

A motor will run without the full functions of the F/R switch and associated microswitches as well as the REED Switch and ITS unit if you just jumper across the controller.

As I said, there are many small items that will render your cart dead.

Check the wiring diagrams and check your system against the diagram that matches your system first. Good Luck.

Thanks for your advise. I've checked the micro switches and run continunity checks on the wiring, but have found nothing wrong. I don't know what a REED switch is. Can you give me more info? Thanks

[jhbluesman]

Originally Posted by BigBlockMan

Is it a1204 controller or a 5 pin 1206 in a 1204 case. Either way we can rebuild it and raise the output if needed

Thanks for your help. I don't know if I have a 1204 or 1206. Can you tell me how to determine the difference?
Thanks

[jhbluesman]

Originally Posted by crash12888

What is the reading on the pot box? That can cause it as well.

Thanks for your help. I don't know what a pot box is. It doesn't have a variable resister that I know of. Do you mean the ITS?
Thanks

[CC-John]

Originally Posted by jhbluesman

Thanks for your advise. I've checked the micro switches and run continunity checks on the wiring, but have found nothing wrong. I don't know what a REED switch is. Can you give me more info? Thanks

The reed switch is a safety interlock switch located in the cart's charger receptical.. They're a common trouble spot.. There is a post on here on how to bypass it, just search "reed switch"...

[jhbluesman]

Originally Posted by CC-John

The reed switch is a safety interlock switch located in the cart's charger receptical.. They're a common trouble spot.. There is a post on here on how to bypass it, just search "reed switch"...

Thanks John,
I'll check it out.

[jhbluesman]

Originally Posted by CC-John

The reed switch is a safety interlock switch located in the cart's charger receptical.. They're a common trouble spot.. There is a post on here on how to bypass it, just search "reed switch"...

CC-John,
I checked the wire for the reed switch. Someone cut it off the receptical box long ago.
I've had this cart for 2 years and it has worked fine until now. What ever was done must have not affected the cart before. If the wire wasn't on there before, do you think it has anything to dlo with my problem now?