Curtis 1264-ITS Motor Controller Installation and Troubleshooting Guide

Quick Guide: Pre-Installation Requirements

Before installing the Curtis 1264-ITS controller, you must perform specific diagnostic checks to ensure the cart and motor are in good working condition. Failure to perform these checks may void the warranty and cause controller failure.

• Motor Winding Check: Disconnect the motor and use a VOM (Volt Ohm Meter) to measure resistance. A1 to A2 should be 0.2Ω–2Ω; F1 to F2 should be 0.8Ω–3Ω; A1 to F1 should be OPEN; F1 to motor case should be greater than 5MΩ.
• Main Solenoid Check: Disconnect all wires. Measure the solenoid coil resistance, which should be 100Ω–250Ω. When energized, the meter should jump from infinity to less than 0.3Ω.
• Wire Harness Inspection: Check all connectors for corrosion, loose, broken, burnt, or missing pins. Repair or replace as necessary.

Wiring and Connections

The controller features various inputs and outputs for system integration. Key connections include the battery pack (B+ and B-), motor armature (A1, A2), motor fields (F1, F2), and various logic inputs such as the Key Switch, Pedal Switch, and Forward/Reverse (F/R) switches. Ensure all connections match the wiring diagram provided in the manual.

Troubleshooting Sequence

For safety, always lift the drive wheels off the ground when troubleshooting. Perform these tests with the Run-Tow/Maintenance switch in the RUN position and the connector attached to the controller. Use a paperclip to 'back probe' the pins from the wire side of the connector.

Key Voltage Tests:

• Pin J1-3 & J1-4: Must be Pack Voltage with the cart in Run.
• Pin J1-2 & J1-7: Must be Pack Voltage with the charger disconnected.
• Pin J1-10 & J1-11: Used for F/R switch logic; must toggle between 0 volts and Pack Voltage depending on switch position.
• Pin J1-1, J1-5, J1-17: Must be Pack Voltage when the Key Switch is ON.
• Pin J1-8: Pedal switch input; must be 0 volts (Pedal Up) and Pack Voltage (Pedal Down).
• Pin J1-15: ITS sensor input; should be approximately 1V (Pedal Up) to 3.5V (Pedal Fully Depressed).

Fault Codes and Diagnostics

The controller features a built-in Status LED visible through a window on the label. When a fault is detected, the LED flashes a 2-digit code continuously. For example, code 3,2 (welded main contactor) appears as three flashes, a pause, and two flashes.

Common Faults:

• 1,1 HW FAILSAFE: Controller defective.
• 1,2 THROTTLE FAULT 1: Wiper signal out of range (ITS fault).
• 1,3 SPEED SENSOR FAULT: No pulses from speed sensor.
• 1,4 HPD: High Pedal Disable fault.
• 1,5 MOTOR STALL: Motor stall at current.
• 2,1 LOW BATTERY VOLTAGE: Battery voltage below threshold or corroded terminal.
• 2,2 OVERVOLTAGE: Battery voltage too high or vehicle operating with charger attached.
• 2,3 THERMAL CUTBACK: Temperature out of range or excessive load.
• 3,2 MAIN WELDED: Main contactor stuck closed.
• 4,3 M- SHORTED: Internal M- short to B-.