Curtis E-Z-GO ITS Controller User Manual

Check Motor Windings:
- Set VOM to RESISTANCE. Measure A1 to A2 (Between 0.3 and
  1).
- Measure F1 to F2 (Between 1 and 2).
- Measure A1 to F1 (Must be OPEN).
- Measure F1 to motor case (Greater than 5M).

Check Main Solenoid:
- Disconnect all wires from the main solenoid.
- Set VOM to RESISTANCE. Measure solenoid coil (Minimum
  100).
- Attach jumpers from main battery to coil and check meter
  reading.
- Reconnect solenoid wiring after testing.
Check the Cart Wire Harness:
- Inspect connectors for corrosion, loose, broken, burnt, or
  missing pins.
- Repair or replace pins as needed.

Additional Information:

It is recommended to replace the solenoid when replacing the
controller. Popular replacement White Rodgers solenoids are
available for convenience.

FAQ

Frequently Asked Questions:

1. What should I do if any of the checked items are
  outside the specified ranges?

If any of the checked items do not fall within the specified
ranges, the controller will fail. These issues must be resolved
before installing the controller to avoid voiding the warranty.

1. What is the troubleshooting sequence for the Curtis
  1205-ITS controller?

All tests should be conducted with the run-tow/maintenance
switch in the run position and with a good battery pack voltage
measurement. Follow the provided troubleshooting sequence step by
step to identify and correct any faults.

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Curtis 1205-117, -210, -211
This sheet is provided to aid in the installation of your remanufactured CURTIS E-Z-GO ITS controller. Upon installation, you may encounter problems that may, or may not, be due to a faulty controller. The following steps must be taken to help diagnose a possible cart fault or faulty controller. An analog or digital volt ohm meter (VOM) will be needed to perform these checks.
WARRANTY WILL BE VOID
If These Steps are Not Performed Before Installing The Control
STEPS TO PERFORM BEFORE CONTROL INSTALLATION
CHECK MOTOR WINDINGS:
Set your VOM to RESISTANCE (). With your motor disconnected, measure A1 to A2. This must measure BETWEEN .3 and 1. With your motor disconnected, measure F1 to F2. This must measure BETWEEN 1 and 2. With your motor disconnected, measure A1 to F1. This must measure OPEN. With your motor disconnected, measure F1 to motor case. This must measure greater than 5M.
CHECK MAIN SOLENOID:
Disconnect all wires from the main solenoid. Set your VOM to RESISTANCE (). Measure the solenoid coil. This must measure NO LESS than 100. Connect VOM leads to the main solenoid lugs. Attach jumpers from main battery positive and negative to the coil (small terminals). Meter must jump from infinity to LESS THAN .3. Remove jumpers and reconnect solenoid wiring from the harness.
CHECK THE CART WIRE HARNESS:
Check the connectors on the wire harness for corrosion, loose, broken, burnt or missing pins. Repair or replace pins as necessary.
IF ANY OF THE ABOVE ITEMS ARE NOT WITHIN THE SPECIFICED RANGES THE CONTROLLER WILL FAIL. THESE ITEMS MUST BE CORRECTED BEFORE THE CONTROLLER IS INSTALLED OR WARRANTY WILL BE VOID.
It is recommended to replace your solenoid at the time of controller replacement. FSIP now stocks popular replacement White Rodgers solenoids for your convenience.
Sheet 1 of 4
77-E-Z-GO 1205-ITS Install Sheet-370 Rev 01 12/6/2024

Battery Pack
Suppression Diode

Reed Switch

Key Switch
(Optional Half Speed Reverse Switch)

Pre-Charge Resistor

Accelerator Switch

Main Contactor

A Motor
Armature
A2

(Optional A2 Connection)

L Main Contactor Coil

Inductive Throttle

Sensor (ITS)

FIELD

B-
Pin 1 Pin 2 Pin 3

B+

Pin 4

M-

–

1205-ITS Troubleshooting Sequence
FOR SAFETY, ALWAYS LIFT THE DRIVE WHEELS OFF THE GROUND WHEN TROUBLESHOOTING!
ALL TESTS ARE CONDUCTED WITH RUN-TOW/MAINTENANCE SWITCH IN THE RUN POSITION AND WITH A GOOD BATTERY PACK VOLTAGE MEASUREMENT.
Attach voltmeter negative (-) lead to main battery for the following tests
Use the following sequence when checking individual pins (don’t skip steps). If you find a fault, do not move on to the next step until the fault is corrected:
Measure the voltage at the main battery positive post (let’s call it Pack Voltage) Pin 1 With Key Switch On, Pedal Depressed, must be pack voltage (and solenoid must click)
– If not pack voltage, check Reed Switch in Charge Receptacle, Key Switch, Accelerator Switch, and wiring for an open condition.
– If pack voltage at pin 1, but solenoid does not click, verify pack voltage across the solenoid’s small
terminals. Repair open wire, or replace solenoid if necessary.
Continued on next page…
Sheet 2 of 4
77-E-Z-GO 1205-ITS Install Sheet-370 Rev 01 12/6/2024

Pin 2 With Pedal Depressed, and Solenoid engaged, must be approximately 12-15v.
– If not ~12-15v, remove Pin 2 wire from controller and measure voltage, should return back to ~1215v.
– If voltage still is not ~12-15v, then replace controller.
Pin 3 With Pedal Depressed enough to make Solenoid Engage, must be ~1.5v.
– If not ~1.5v, check wiring and ITS for an open condition.
Pin 3 With Pedal Fully Depressed, must be ~2.5v.
– If not ~2.5v, check wiring and ITS for an open/short condition.
OPTIONAL INPUTS: Pin 4 With Cart Set in Reverse and Half Speed Reverse input present, must be ~Pack Voltage
– If not ~Pack Voltage, check Half Speed Reverse switch for an open/short condition.
M- Post With Accelerator slightly depressed, just where the solenoid first clicks, verify M- post reads battery
voltage. Then, as the accelerator continues to be depressed to full throttle, M- voltage reading should drop towards 0v, with the motor running at full speed.
– If M- post does not show B+ voltage when solenoid first energizes, check the wiring to/from the Main Contactor, thru the Motor Armature winding, thru the F&R switch and the motor field winding as shown on the wiring diagram.
Helpful Hints DO NOT UNDER ESTIMATE THE IMPORTANCE OF MOTOR RESISTANCE CHECKS AND MAIN SOLENOID CHECKS.
MANY CART ISSUES ARE CAUSED BY BURNT/DAMAGED BRUSHES THAT WILL BE FOUND AS PART OF THE ARMATURE RESISTANCE CHECK. ALSO A SHORTED ARMATURE AND FIELD WITHIN THE MOTOR WILL DAMAGE THIS CONTROLLER.
Flight Systems Industrial Products also offers the following Technical Support options …
Troubleshooting Manuals / Codes www.shop.fsip.biz/en/content/technicaldocuments
Live Tech Support Chat www.fsip.biz
Technical Support Forum fsip.websitetoolbox.com
Phone Support 1-800-333-1194 (Option 4)
Sheet 3 of 4
77-E-Z-GO 1205-ITS Install Sheet-370 Rev 01 12/6/2024

PRE-INSTALLATION INSTRUCTIONS MUST BE FOLLOWED OR WARRANTY
WILL BE VOID
IMPORTANT! TROUBLESHOOTING INFORMATION
INCLUDED IN THIS PACKET

Documents / Resources

Curtis E-Z-GO ITS Controller [pdf] User Manual
E-Z-GO, E-Z-GO ITS Controller, ITS Controller, Controller

References

User Manual

E-Z-GO ITS Controller

Product Information

Specifications:

Product Usage Instructions

Steps to Diagnose Potential Issues:

Additional Information:

FAQ

Frequently Asked Questions:

Documents / Resources

References

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