new controller and new solenoid still no go!

larryo587

I have a 91 36volt marathon cold control went up in smoke so i just replaced it with a new one and changed the solenoid but no go. The solenoid clicks and i here a slight whinning sound sounds like from the motor tires barely make a twitch in forward or reverse. What should i troubleshoot and in what order

BGW

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cgtech

Take that motor off and inspect it before you fry a new controller. Sounds like brushes are gone.

larryo587

Tried another motor known good from my 2001 series ezgo. Still no go. I did the test on the solenoid and it tests good. What other testscan i do to find out why there is no go.

JohnnieB

If the solenoid is clicking, the problem is in the high current circuit.


Measure and record the pack voltage.

Connect your voltmeter test leads between the controller's B- and M- terminals.

If you have a pre-charge resistor on the solenoid, you should read a couple volts less than the pack voltage.

Press pedal just far enough for solenoid to click. You should now have FULL pack voltage.

If you don't have full pack voltage, trace the high current path through the cables, connections, contacts and components until you find it.

If you do have full pack voltage, press pedal to floor and the voltage between B- and M- should decrease to Zero, or very close to it.

If the voltage does not decrease to zero, check the throttle input to controller.

If throttle is good, the controller is bad.

scalpem15

How would you test the throttle?

JohnnieB

Disconnect the black and the white wires on top of the controller.
Measure between the disconnected wires with an Ohmmeter.

Should be close to 0Ω with pedal up and upwards of 5,000Ω with pedal on floor. (If F/R is is R, the Ohmic range may be 0-2.5kΩ rather than 0-5.0kΩ - half speed reverse option.)

Also, watch meter while pushing pedal down slowly, there increase in Ohms should be smooth and gradual. Dead spots and spikes can shut controller down.

If the controller sees about 7,000Ω or over from the pot-box, it shuts down to prevent a runaway cart.

larryo587

The voltage between m- and b- is the same as pack until i push the pedal it jumps all the way to 120 whats up with that

scottyb

Replace the battery in your meter and re test.

larryo587

I have 99 volts when pedal is depressed touching s1 and s2 on motor. Only 3 between a1 and a2

scottyb

These readings are not correct. try a new battery