Installation and Troubleshooting Guide for Curtis 1268-ITS Controller

Quick Guide from the Manual

This document provides critical pre-installation checks and troubleshooting procedures for the Curtis 1268-ITS controller. Warning: Failure to perform the specified pre-installation checks will void the warranty and may cause controller failure. Always lift the drive wheels off the ground when troubleshooting.

Pre-Installation Checks

Before installing the controller, perform the following tests using a Volt Ohm Meter (VOM):

• Motor Windings: With the motor disconnected, measure resistance between A1-A2 (0.2Ω to 2Ω), F1-F2 (0.8Ω to 3Ω), A1-F1 (Open), and F1 to motor case (>5MΩ).
• Main Solenoid: Disconnect all wires. Measure coil resistance (100Ω to 250Ω). When energized, resistance should drop from infinity to less than 0.3Ω.
• Wire Harness: Inspect all connectors for corrosion, loose, broken, burnt, or missing pins. Repair or replace as necessary.

Wiring and Connections

The controller requires specific connections for the battery pack, motor armature, motor field, speed sensor, and various switches (Run/Tow, Mode, Key, Pedal). Ensure all connections match the provided wiring diagram, specifically noting the pin assignments for the J1, J2, and J3 connectors.

Troubleshooting Sequence

When troubleshooting, ensure the Run/Tow switch is in the RUN position and the connector is attached to the controller. Use a paperclip to 'back probe' the pins from the wire side of the connector. Follow this sequence:

• Power Checks: Verify Pack Voltage at pins J1-3 and J1-4.
• Charger Interlock: Verify Pack Voltage at J1-2 and J1-7 with the charger disconnected.
• Directional Switches: Check F/R switch inputs at J1-10 and J1-11.
• Key Switch: Verify Pack Voltage at J1-1, J1-5, J1-17, and J1-6 when the key is ON.
• Pedal Switch: Verify voltage at J1-8 (0V with pedal up, Pack Voltage with pedal down).
• ITS Sensor: Verify 14-15V at J1-13. Check signal at J1-15 (approx. 0.8V pedal up, 2.0V pedal fully depressed).

LED Diagnostics

The controller features a built-in Status LED that flashes 2-digit fault codes. Common codes include:

• 1,2: Throttle Fault (ITS signal out of range).
• 1,3: Speed Sensor Fault (No pulses).
• 2,3: Thermal Cutback (Over/under temperature).
• 3,2: Main Welded (Main contactor stuck closed).
• 3,4: Field Missing (Motor field wiring loose or open).

Helpful Hints

Do not underestimate the importance of motor resistance checks. Many cart issues are caused by burnt or damaged brushes. A shorted armature or field within the motor will damage the controller. If you encounter issues, consult the full troubleshooting chart for specific fault explanations and causes.