1992 EZGO marathon intermittently won’t run

[Bocephus10]

Hey guys and girls, I’m new to the forum and am so thankful for the vast amount of info and help on here. I’ll get to my issue. My client had a 1992 EZGO Marathon golf cart that I runs on a 36v system. Lately it’s been intermittently dying while driving it. I’ve searched the various threads here and just wanted some clarification on what to check next and how exactly. My client just replaced the whole battery bank with 6 new batteries. I checked each cell and the total bank voltage and all looks good. Referencing a prior post it says I should read about 38v total and approx 6.32v individually. I also checked the M- and B- terminals then dumped the pedal and saw bank voltage. I believe that’s normal. We also replaced the solenoid and still it happens intermittently. I’ve checked all wiring and terminals. All seem clean and tight. Solenoid clicks when pedal is pressed and voltage is present like previous posts have instructed. I’ve tried jacking the rear end and pressing the pedal and wiggling wires. Also looked at F/N/R selector and that seems fine. It does run at times then just quits. Not sure what to do next. We replaced a whole bank of batteries and a solenoid and still have the problem. My client is getting tired of throwing more money into this. Any ideas or tips on what I can check or test next?

[JohnnieB]

Originally Posted by Bocephus10

Hey guys and girls, I’m new to the forum and am so thankful for the vast amount of info and help on here. I’ll get to my issue. My client had a 1992 EZGO Marathon golf cart that I runs on a 36v system. Lately it’s been intermittently dying while driving it. I’ve searched the various threads here and just wanted some clarification on what to check next and how exactly. My client just replaced the whole battery bank with 6 new batteries. I checked each cell and the total bank voltage and all looks good. Referencing a prior post it says I should read about 38v total and approx 6.32v individually. I also checked the M- and B- terminals then dumped the pedal and saw bank voltage. I believe that’s normal. We also replaced the solenoid and still it happens intermittently. I’ve checked all wiring and terminals. All seem clean and tight. Solenoid clicks when pedal is pressed and voltage is present like previous posts have instructed. I’ve tried jacking the rear end and pressing the pedal and wiggling wires. Also looked at F/N/R selector and that seems fine. It does run at times then just quits. Not sure what to do next. We replaced a whole bank of batteries and a solenoid and still have the problem. My client is getting tired of throwing more money into this. Any ideas or tips on what I can check or test next?

If the red highlighted statement means the voltage between the B- and M- terminals stayed at pack voltage when pedal was pressed to floor, it is abnormal.

Normal readings are:
1. When the pedal is pushed just far enough to make solenoid click, you should read pack voltage.
2. When pedal is pushed to the floor, you should read zero volts.

If you're getting pack voltage with pedal on the floor, either the throttle or the controller is bad.

[Bocephus10]

Thanks JohnnieB. I will verify it’s only bank voltage at initial solenoid click and not all the way down which you say should be zero. If the voltages are ok as you described what would be the next thing you recommend checking?

[Bocephus10]

Originally Posted by JohnnieB

If the red highlighted statement means the voltage between the B- and M- terminals stayed at pack voltage when pedal was pressed to floor, it is abnormal.

Normal readings are:
1. When the pedal is pushed just far enough to make solenoid click, you should read pack voltage.
2. When pedal is pushed to the floor, you should read zero volts.

If you're getting pack voltage with pedal on the floor, either the throttle or the controller is bad.

If voltage is good like you describe in your response, what would be the next thing to check?

[JohnnieB]

Originally Posted by Bocephus10

If voltage is good like you describe in your response, what would be the next thing to check?

Throttle