Curtis controller problem

carpenter · 08-31-2022, 04:08 PM

2002 club car ds, series motor. Controller is a Curtis 1204-410. Cart is slow as a snail. Controller out put is 45.4 volts. With new mcor it still runs the same. I'm reasonably sure controller is bad. Where is the best place to send for rebuild or does anyone have one to part with? I've found a few rebuild places on the net, do any of them stand out above the others? thanks,

Tom47 · 08-31-2022, 05:43 PM

What is your pack voltage 12 hours after the charger cycles off?

carpenter · 08-31-2022, 07:14 PM

51.5 volts

Tom47 · 09-01-2022, 04:32 PM

The voltage is excellent. I would recommend hooking the VOM across the pack with some alligator clips and see what the voltage does when you are driving it.

Then hook the VOM to terminals S-2 and A-2 on the motor. In forward you should read pack voltage at max throttle. If you are reading less than full pack voltage, it could be a bad controller unless you are not getting 100% throttle.

The next step is to check the MCOR output resistance. Disconnect the three wire plug at the MCOR and remove the main pack positive wire for safety.

With the VOM on 20,000 ohm scale, check the resistance from the #2 pin (the one that goes to the white wire in the harness) to the other two pins in the MCOR. You should have 0 ohms with one combination and 5000 ohm with the other combination.

After each check above, have someone slowly push the pedal all the way to the floor. The resistance should climb from 0 to 5000 ohms with one combination and drop from 5000 to 0 with the other combination.

These ohm readings are nominal and can vary somewhat. Advise what your readings are.

greg-g · 09-02-2022, 10:50 AM

What you have described would be an unusual failure for a controller. as stated above I would check my throttle input, weather New or Old. also I would put a meter on the batteries and drive it hard and see what the voltage drops to, usual failures are a complete blowout or short

LukeL · 09-02-2022, 11:37 AM

How slow is "slow as a snail?" In my experience max stock speed for those 48v powerdrive carts is around 12mph.

meimk · 09-02-2022, 12:04 PM

I have a 2000 DS in the shop right now, same controller, same symptoms. Maybe 5 or 6 mph when it trips up. MCOR tests good, controller out only about 25 volts when it acts up. I just sent the controller out to FSIP.

08-31-2022, 04:08 PM	#1
carpenter Not Yet Wild Join Date: Sep 2010 Posts: 2	Curtis controller problem 2002 club car ds, series motor. Controller is a Curtis 1204-410. Cart is slow as a snail. Controller out put is 45.4 volts. With new mcor it still runs the same. I'm reasonably sure controller is bad. Where is the best place to send for rebuild or does anyone have one to part with? I've found a few rebuild places on the net, do any of them stand out above the others? thanks,
carpenter Not Yet Wild Join Date: Sep 2010 Posts: 2

08-31-2022, 07:14 PM	#3
carpenter Not Yet Wild Join Date: Sep 2010 Posts: 2	Re: Curtis controller problem 51.5 volts
carpenter Not Yet Wild Join Date: Sep 2010 Posts: 2

09-01-2022, 04:32 PM	#4
Tom47 Gone Wild Join Date: Dec 2016 Location: Kingsland, Georgia Posts: 1,825	Re: Curtis controller problem The voltage is excellent. I would recommend hooking the VOM across the pack with some alligator clips and see what the voltage does when you are driving it. Then hook the VOM to terminals S-2 and A-2 on the motor. In forward you should read pack voltage at max throttle. If you are reading less than full pack voltage, it could be a bad controller unless you are not getting 100% throttle. The next step is to check the MCOR output resistance. Disconnect the three wire plug at the MCOR and remove the main pack positive wire for safety. With the VOM on 20,000 ohm scale, check the resistance from the #2 pin (the one that goes to the white wire in the harness) to the other two pins in the MCOR. You should have 0 ohms with one combination and 5000 ohm with the other combination. After each check above, have someone slowly push the pedal all the way to the floor. The resistance should climb from 0 to 5000 ohms with one combination and drop from 5000 to 0 with the other combination. These ohm readings are nominal and can vary somewhat. Advise what your readings are.

09-02-2022, 10:50 AM	#5
greg-g Gone Wild Join Date: Aug 2011 Posts: 553	Re: Curtis controller problem What you have described would be an unusual failure for a controller. as stated above I would check my throttle input, weather New or Old. also I would put a meter on the batteries and drive it hard and see what the voltage drops to, usual failures are a complete blowout or short
greg-g Gone Wild Join Date: Aug 2011 Posts: 553

09-02-2022, 11:37 AM	#6
LukeL Gone Wild Join Date: Jun 2017 Location: Savannah, GA Posts: 6,539	Re: Curtis controller problem How slow is "slow as a snail?" In my experience max stock speed for those 48v powerdrive carts is around 12mph.

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08-31-2022, 05:43 PM	#2
Tom47 Gone Wild Join Date: Dec 2016 Location: Kingsland, Georgia Posts: 1,825	Re: Curtis controller problem What is your pack voltage 12 hours after the charger cycles off?

09-02-2022, 12:04 PM	#7
meimk Gone Wild Join Date: Jun 2011 Location: Northern Indiana Posts: 2,823	Re: Curtis controller problem I have a 2000 DS in the shop right now, same controller, same symptoms. Maybe 5 or 6 mph when it trips up. MCOR tests good, controller out only about 25 volts when it acts up. I just sent the controller out to FSIP.

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