92 ezgo electric, position one smoking

mael5trom

Hi all, newbie here. Ive searched through the forums, and almost over the entire internet and well.. I'm perplexed and frustrated. Wife talked me into trading my four wheeler for this golf cart, because it'd be more usefu to everyone.

What I got... A 92 ezgo marathon, resistor style electric cart. It's been lifted with Jake's products, has larger tires, radio, LEDs , etc.

Things I've done since purchased.. replaced the 3 deep cycle marine batteries the guy had installed at purchase. Replaced with 6, 6v Duracells from Sam's. I've also replaced the solenoid, as it fried up one day to point post just fell out or the equipment.

I've also replaced the resistor coil assembly , replaced the swiper board, and the contact.

So...the problems. First things, I screwed up installing the resistor coil and put it in backwards. I quickly figured this out by its glowing greatness after a ride or two
. I thought it was breaking in, and posts said they do get hot... Well mine got so hot it started a small fire on my new coil and gave the board some personality. Averted this catastrophe, got cart home and reversed the coil.

It was at this time I learned that it's really best to WOT these carts, or coast. Because, when WOT the resistor should be out of the electrical path and just battery to motor moving the cart. So I changed my driving habits, and it seemed to help a bit but I still would smell the coil and feel heat even with new driving style. This driving style isn't always conducive to driving in the woods, and places where it's more bumpy and shouldnt subject the under carrige to the such onslaught and possible damage... so drivers will inevitably use position 1 to 3.. especially the kids..

Fast forward to today.. I told my buddy about how he needs to drive this thing using WOT and then coast. Following him on the four wheeler, he did you everything exactly as prescribed. Now, it was about an hour of traveling, with some breaks in between (because the cart smelled hot) .. we make it to our destination, sit down.. relax.. and just lingering in the man cave, sipping a beer, and about three minutes later notice smoke coming from cart.

Position one of coil (closet to front of cart is smoking again!!) And on fire... I get it out.

Things I checked after latest incident.

Depressing pedal to floor makes contact with 5th wiper, and not touching the fourth pad; centered perfectly. However I did notice pad four and five and really **** close (could it be passing energy? )

I've tried to find some accurate wiring diagram to verify I have things wired right but each one really seems to be lacking. So I'll explain.

Pad 1 has no wire, and this is default pedal position contact
Pad 2 has a wire to motor, and wire to Sol.
Pad 3 to motor
Pad 4 that motor
Pad 5 to motor

Some observations and thoughts

It feels like the cart is a bit slower than it should to be. I think it gets to 12 mph. Has good torque

Also, it seems the coil isn't being removed from path at WOT.

Please help me figure this out. I just want to have some **** confidence that company or my kids can use this toy when I'm not there to keep an eyes on it.. to put out fires or coach how to drive it.

Thanks in advanced

BGW

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BobBoyce

With your situation, it might be a good idea to consider upgrading your cart to an electronic speed control. This would likely be safer for yourself and others using the cart, with the history of fires.

I had a similar issue with an old cart that had the resistor speed control. Instead of an electronic speed control (not yet available back then) option, I installed a bank of solenoids that were switched by the speed control board, and ran heavy cables from those solenoids to the resistor wires, which I had relocated to where they were better cooled by airflow when driving. This eliminated the high current switching at the speed control itself, which stopped the board from burning and getting carbonized.

Bob

mael5trom

So from what i describe youre not feeling there is a problem, beside the design and use case. I guess that it good, but this cart is like a noat to me at this point.. Break Out Another Thousand.

Let me ask. Few questions.

Id like a bit more speed, and its my understanding that stock motors ib these ezgos can handle a bit more. This true?

Can i keep the torque and get some more speed?

I just bought these 6 volts so i have no interest until they die to replace with 8s, will i be able to see a little bit of reality i ask for above with these batteries after conversion?

We do a bit of off roading, and a couple extra passengers. What would you folks recommending me purchasing and from where? First place or two i looked at had no kits for my ezgo

While im here.. i am looking for new charger that is from this century. What do you recommend?

JohnnieB

1. You mentioned larger tires. Tires taller than stock (18") give more speed, but take away torque and in the process, causes the motor to draw more amps, which in turn make the resistor coils run hotter. Not a good combination for driving through tall, dry grass.

2. The 36V DC motors in most EZGO carts actually run better at 42V and 48V, but I'm not sure about the motor in a 92 Marathon.

3. Only by increasing the battery pack voltage or changing motors. As previously mentioned, going to taller tires will increase the speed, but reduce the torque where rubber meets road.

4. You might be able to add one or two more Sam's Club batteries that match the 6 already installed in the bag well to get either 42V or 48V. Then go to 6 x 8V when they need replacing.

5. Here is a source of tried and true conversion kits: http://www.cartsunlimited.net/conversion-kits.html

6. Here is a source of the best cart battery charger on the market: http://www.cartsunlimited.net/battery-chargers.html

Also, attached is a parts manual for your cart.

Attached Files

X-440, X-444, X-444F, Electrick Golf Car, 1992, 27148G01.pdf (7.25 MB, 0 views)