2006 Star Classic 4 + 2

Since January 2021 I have been unable to repair this cart.

In early October 2020 my son-in-law drove my 2 year old grand daughter to the grocery store in this 2006 Star Classic Golf Cart. When they came out the cart would not move under it’s own power.

To skip to just the facts: https://johnblake.online/specs-tests-and-results/

He had it towed to the Star Golf Cart dealer for repair. After about 2 months when he inquired about the cart he was told that it might be the controller or the wiring harness but they weren’t sure. They thought it could cost about $2000 to repair. He had them return the cart to his house.

I picked it up at his house and towed it to my automotive repair shop and that’s when my golf cart education began.

When the key is turned on the controller blinks 3-4. This is a Curtis Controller #1244-5461. And code 3-4 is “Missing contactor”. The obvious next step is to replace the contactor (another word for a heavy duty relay). I believe the repair shop may have tried replacing the relay because it looks new. It’s a 48 volt Albright SW80B-156 contactor. The resistance across the coil windings reads 216Ω. When I apply 48 volts and ground the contactor pulls in firmly and the resistance across the power terminals reads .1Ω. There does not appear to be an internal resistor or diode in the contactor. After testing the contactor, verifying that there is 48 volts applied to the controller and contactor when the key is turned on and there is a good connection from terminal 17 (main contactor driver output) to the ground side of the contactor, I sent the controller to Cloud Electric to be rebuilt ($340+shipping). It was returned after no problem was found during testing. I installed it and still had the same code. After re-checking everything I had done before plus everything else I could think of, I requested authorization to have it re-tested. They asked me to check the field winding resistance, motor, armature, brushes, and check for voltage on the frame rail. Everything tested correctly so they authorized a return to have it retested. However, they could not find anything wrong with it. I still could not find any problems with the wiring or contactor so I ordered a new controller. It still has the factory QC seal and I believe it is new old stock. Unfortunately, after installing it, I still have the same 3-4 code.