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Old 06-19-2019, 07:30 PM   #1
Langland
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Join Date: Jun 2019
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Default Golf Cart Controller Advice Needed

I have a 1999 E-Z-Go
Model: TXT
Drive System: DCS

This is an electric 36 volt cart.

Problem: The cart slowly died over several months. Step on the pedal and it won't go in forward or reverse. Wheels don't even try to turn even while on jacks. (The cart will roll freely, so it's not the breaks.)

Where I'm at: I did a lot of stuff (see below) and I'm down to the controller.

Advice on WHERE to buy a controller is much appreciated. Should I get a remanufactured one or a new one? Any and all other advice is welcome. No enhanced performance needed. My dad uses it to get around a flat 1/2 acre yard to take of his chickens and garden

Stuff I did already:
1) I checked battery pack voltage (38.4) and each battery (6.4)
2) Repaired corroded wire (red w/ white stripe) from the reed switch.
3) Replaced bad solenoid (I benched tested it.)
3a) Benched tested the new solenoid (tested Good).
4) Replaced bad (cracked) Inductive Speed Control (ISC)
5) Traced and performed continuity test on all wires. All good, 0 ohms.
6) Tested Forward and Reverse micro switches. Good.
7) Tested pedal switch. Works great. Also swapped it out with a new one to test, but I kept the old one in because it is better quality.
8.) Tested key switch. Showed some resistance but eventually settle to 0 ohms. (Also bypassed it with jumper wire)
9) Tested Run/Tow switch. Good.
10) Replaced the diode/resistor thingy on the solenoid.

11) Had the motor refurbished/rebuilt. I did a continuity test on the two wires (black and white) coming from the controller going to the motor. Before refurb it a had a resistance of 14 ohms. After refurb it had zero resistance.

Before refurb, I jacked up the cart and tested the motor with 12 and 18 volts; wheels didn't turn without me helping and then it would stop immediately. After refurb, I tested again and the wheels turn fine, as it should. So I'm confident in the motor at this point. (And by testing I mean I bypassed everything and attached power directly to the motor. Single wire connects S1 to A2. Negative from the battery goes to A1 and Positive goes to S2. I used car jumper cables to connect the battery to the motor.)

Like I said. I'm down to the controller. As far as I know that's all that's left.
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Old 06-19-2019, 07:42 PM   #2
JohnnieB
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Join Date: Jun 2011
Location: West Virginia
Posts: 19,654
Default Re: Golf Cart Controller Advice Needed

You connected the sepex motor as a series motor, but it ran, so it ought to be okay.

The DCS controller (Curtis 1206SX) is a high failure item, it has no under-voltage protection. It was replaced by the PDS five years after it was introduced.

Replace it with an Alltrax XCT48400DCS controller. It is user programmable, so you can tone it down for your dad's needs.
Attached Images
File Type: jpg Motor Test - Sepex.jpg (91.7 KB, 0 views)
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Old 06-19-2019, 07:48 PM   #3
Langland
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Default Re: Golf Cart Controller Advice Needed

JohnnieB

Thank you! I truly appreciate it.

Do y'all recommend places to buy from online?
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Old 06-19-2019, 08:01 PM   #4
scottyb
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Location: Southern California
Posts: 73,358
Default Re: Golf Cart Controller Advice Needed

I don't recommend investing in any rebuilt or repaired controller. These units are not rebuilt but repaired, so they are 98% old components, in which case you are buying 20 year old components.
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Old 06-19-2019, 08:07 PM   #5
Langland
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Default Re: Golf Cart Controller Advice Needed

Good point, scottyb.
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Old 06-19-2019, 08:10 PM   #6
yurtle
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Default Re: Golf Cart Controller Advice Needed

I bought all of my goodies from ScottyB, a site sponsor and frequent contributor. Best prices and great customer service.
https://www.cartsunlimited.net/
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Old 06-20-2019, 02:52 PM   #7
JohnnieB
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Default Re: Golf Cart Controller Advice Needed

Quote:
Originally Posted by Langland View Post
JohnnieB

Thank you! I truly appreciate it.

Do y'all recommend places to buy from online?
I bought nearly all my upgrade stuff from: https://www.cartsunlimited.net/alltrax-xct-sepex--.html

Of course, if it is something he doesn't sell, I go to one of these: http://www.buggiesgonewild.com/site-sponsors.php
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