Curtis 1219-4860 PMC controller repair

[GriffinRU]

Hello RC-Monsters,
Long time no see - I plan to come back again :)

This time, would like to share with you recent Golf cart (Cushman Hawk) Curtis controller repair - upgrade / mod (not like mamba Mod but might be cool to check...)

Didn't capture entire process, but in the middle pull the camera out and of we go...

What was wrong or how we break it:
-start with replacing brake pads -> end up with blown controller (quick switch from FWD to REV while 2000lb cart was moving wasn't a good idea, but smashing into other car would be worth... :)
So, upon restart 3+1 error code, stating your motor locked or drivers out - let me guess Big DC motor vs FETs - you got an answer.

Taking controller apart:
-it was easy (after removing from golf cart) rear panel was lost some time ago, so it was clear which screws to loose and what to push...
-once you have "monster" (by 99 standards) board assembly out all you need is to separate CPU board from FET's board
(Sounds so familiar, right)
-10-pin header to unsolder, 4 plastic standofs and black compound to break:


-no pictures on how to remove FET's - sorry
but here they are:


NEXT step - to Find replacement for 1998 FET - I selected IRFB4410ZPBF MOSFET N-Ch 100V 97A TO-220 -> close enough - better part - cost/availability - 28 fets

Note: replace them all with the same part!

Other parts like CR4180R diodes (more like MR2500) and lots of 1000uF 68V caps were checked and no problems were found.

Note: DO NOT TAKE EVERY TO-220/DIODE PART OF THE BOARD - TO PRESERVE HEATSINK SPACING!!!

-Complete FET's replacement and clean-up:



to be continued...