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Old 07-25-2021, 02:10 PM   #31
egad
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Join Date: May 2021
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Default Re: Melex 252 Curtis controller 1204 bad?

Wow, you are correct. I removed the controller and found burn marks where one of the six screws were in contact with the mounting plate. I insulated the screws and now we are back to square one. I hit the throttle and only click from solenoid. 0 volt between b+ and m- on the controller when i push the throttle. Full voltage between b- on controller and battery b+ Terminal.
Need to disassemble the controller again and check the connections on the newly soldered parts. Any other parts on the controller known to be faulty?
Thank you again for all the help!
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Old 07-25-2021, 02:12 PM   #32
egad
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Default Re: Melex 252 Curtis controller 1204 bad?

Pics from short in screws under controller:
Attached Images
File Type: jpeg EF5DF491-DBBD-43F8-83CC-6F21DFA75766.jpeg (231.2 KB, 0 views)
File Type: jpeg 2EF86885-3B71-40CC-B6D0-3BF3253CFD53.jpeg (377.3 KB, 0 views)
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Old 07-29-2021, 01:11 AM   #33
egad
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Default Re: Melex 252 Curtis controller 1204 bad?

Thinking out loud, but could a faulty ksi lead to these problems?
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Old 07-29-2021, 05:03 AM   #34
egad
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Default Re: Melex 252 Curtis controller 1204 bad?

Another thing, i have 3 12v batteries. The battery in the ”middle” is connected from b- to the cart frame. Is this correct?
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Old 07-29-2021, 01:46 PM   #35
egad
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Default Re: Melex 252 Curtis controller 1204 bad?

Ok, i changed the fuse on the blue cable going from large +terminal on solenoid. I connected the batteries and the cart runs like normal :D. The bad news is that i noticed smoke, and quickly disconnected the b+ terminal.
My conclusion is that with key off, gear in forward the resistor on top of the solenoid is getting hot in a few seconds. Gear in neutral key off resistor is not getting hot.

Short in the controller?
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Old 07-30-2021, 07:23 AM   #36
trevdalocal
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Default Re: Melex 252 Curtis controller 1204 bad?

Quote:
Originally Posted by egad View Post
Another thing, i have 3 12v batteries. The battery in the ”middle” is connected from b- to the cart frame. Is this correct?
Can you post a picture of how your batteries are wired? I'm not sure about your particular cart, but that doesn't seem right, the batteries should be in series, connected to each other beside the first and the last terminals in the string.
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Old 07-30-2021, 08:02 AM   #37
biphase
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Default Re: Melex 252 Curtis controller 1204 bad?

A short in the controller would cause that resistor to get hot whenever the cart was in gear and the solenoid was not closed.

When the cart was running did you have full control of the speed with the throttle? Did the cart stop running altogether or will it still run normally when you step on the pedal?
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Old 07-30-2021, 04:09 PM   #38
egad
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Default Re: Melex 252 Curtis controller 1204 bad?

I didnt want the cart to be connected to the batteries or too long, but when i tested it it seemed to work OK.
I did however manage to solve the problem. I dissasembled the controller, and found that one of the connectors that connect the logic board to the main board(the ones with 3 legs) were connected to eachother. I resoldered them and now the cart is working fine.
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Old 10-03-2021, 02:37 PM   #39
cristianlari@yahoo.es
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Default Re: Melex 252 Curtis controller 1204 bad?

Buenas, tengo un MELEX 252 serial 190000, alguien tiene un esquema eléctrico, hay algún cable roto y no soy capaz de comprobar el circuito.
Alguien me puede ayudar.
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