Faulty Controller

[williamsent]

I just finished a complete restoration of a 93 Club Car DS that was flooded during Hurricane Irma. I went through and replaced everything electric from the key switch to the motor. Basically, everything except for a few of the activation wires is brand new. I upgraded to 48v and installed new Trojan batteries, AMD 11 hp 48VDC High Torque motor “The Beast”, Curtis 500 AMP controller 1205M, 48v high amp Solenoid Curtis SW180B, beefed up 48v F&R switch assembly, a new V Glide Assembly, and new 4ga weld cable set. Although new to golf carts I have always worked on all my toys from boats to automobile and used to do a lot of stereo installation. Anyway, I got everything together but could not get the cart to go. Only a click at the solenoid. After numerous calls to the help line where I ordered the parts and going through the wiring diagrams several times checking the wiring, I finally gave up and called a repairman. When he came out and went through everything again, he found that the Curtis controller had not been programmed. Apparently, this unit has 9 different optional settings. He programmed the unit for me and explained that all my wiring was correct. He only charged me for an hour labor and no service call fees. I was very happy and have enjoyed the cart for about two weeks now. UNTIL yesterday. My wife was driving the cart through our back yard and it just died. Doing the exact same thing that it was doing before the controller had to be programed. Just a click at the solenoid in forward and reverse. 100% Charge at the batteries. No loose wires found so far. I am going to go through it all this weekend again. Its much harder now that the cart is together, but if no luck I guess I will call the repairman out again. Any suggestions of what I should look for? I am wondering if I have a faulty controller. Anyone had a similar issue? Thanks in advance.

[NoleFan4Ever]

That is correct for an "M" series controller as they require programming by a Curtis Hand-Held for all the logic inputs. They do not just lose them so it is probably another issue. You need to start at one place and go from there as you are looking for the culprit. I would start with the solenoid. (and shame on whomever you purchased from for not programming to your cart - that is why I like an Alltrax - You do it all with your own laptop PC)

Check to see if it is actually closing or just clicking. With everything off and static, get you a DVM and get on the 2 large posts and you should see somewhere around ~.5 volt to a little over 1 volt (as long as you have the resistor in place). Now with the key On, Fwd selected, and the Go Pedal depressed, you should hear the solenoid click. If it did close, the voltage should read 0vdc. If it does not, hit it with the but of a hammer handle a few time to free it. If it still will not close, it has failed and will need to be replaced. If it did close and shows 0vdc across the 2 large posts, next check would be the throttle signal and then next the controller output.

[WalterM6]

This is a real good reason to buy an Alltrax.

[williamsent]

Well this was my first cart and I bought the components as a kit. Thanks for the should have though. I already have the second cart that I will rebuild. I'll probably do things differently this time, but need to figure out what happed with this one right now.

[Htownblue]

Originally Posted by williamsent

Well this was my first cart and I bought the components as a kit. Thanks for the should have though. I already have the second cart that I will rebuild. I'll probably do things differently this time, but need to figure out what happed with this one right now.

You need to isolate the problem. Find out if when the solenoid engages, are you getting pack voltage at both terminals. I think you either have a Solenoid issue or an issue with the controller is what my best guess is. You in theory could have an issue with your MCOR throttle signal or your F/R switch not engaging properly which would cause the controller to fail to send voltage to the motor.

[NoleFan4Ever]

Originally Posted by williamsent

-snip-
but need to figure out what happed with this one right now.

Umm.... Post #2???

[williamsent]

Was just saying I have another cart that I am going to rebuild and may go with alternate components. Just trying to figure out the problem with my current project. Plan to get out there today and try to run down the problem. Will call the shop tomorrow if I cant figure it out. I am pretty good at following directions but I'm just not familiar enough with golf carts to troubleshoot. Thanks for the suggestions.

[williamsent]

Problem solved. Just a loose wire at the controller. Thank goodness. The only thing I did not replace on this darn thing was a few of the activation wires. One of the female connectors I did not replace was loose. Perhaps now is a good time to at least replace the rest of the connectors. Should have done it with the body off I guess. Thanks for your help guys!

[NoleFan4Ever]

If they all could be so easy.... Good deal.

[Mooncarter]

Originally Posted by NoleFan4Ever

If they all could be so easy.... Good deal.

Yep. Got lucky.