Marithon jerking

Helirich · 09-13-2015, 05:37 PM

My Marithon was giving indications of dead batteries. (They are 7 years old) but I got a new cart project with new batteries. So it only has to last a few more weeks.

So I was using it and it started jumping. Like turning on and off a couple times a second. It would jerk so hard, I thought it might hurt something. I towed it back to the shop. I found the rear right battery and the controller mount had tilted down. The bottom was all rusted out. I had fixed some rust years back, but this area was not bad. Now it is.

Anyways I figured the throttle rod was not working proper because the whole controller was moving. I took it all apart and rebuilt the battery suports and mounted the controller good.

Got it all back together and went to back out of the shop and it started going, but wouldn't stop when I let off the pedal. (The pedal came back up) So I switched it from reverse to forward. It stopped. Then when I pushed the pedal, it started jerking again. I also detected some smoke.

I'm thinking of pulling the motor unless you guys point me somewhere else. This sucks because I want to work on my new cart. But I have to have a working cart for my wife before I tare into the new one.

Helirich · 09-14-2015, 09:36 AM

Ok, today I jacked up the cart and turned on the key. There was immediately some popping sound and some smoke. The smoke came from the bottom of the controller. I looked underneath and taped on the bottom of the controller. The cap came off and smoke came out.

I didn't realize that there was a cap on them. I thought it was all solid state. (Full of epoxie) In any case, would I be correct to assume it's shot? I mean, nobody works on them, do they? It's just a standard controller. So can't be worth much.

I might pull it apart and take some pics. But I'll wait a couple days and see if someone tells me to spry some bleach in there to fix it. LOL

JohnnieB · 09-14-2015, 10:00 AM

Quote:

Originally Posted by Helirich

Ok, today I jacked up the cart and turned on the key. There was immediately some popping sound and some smoke. The smoke came from the bottom of the controller. I looked underneath and taped on the bottom of the controller. The cap came off and smoke came out.

I didn't realize that there was a cap on them. I thought it was all solid state. (Full of epoxie) In any case, would I be correct to assume it's shot? I mean, nobody works on them, do they? It's just a standard controller. So can't be worth much.

I might pull it apart and take some pics. But I'll wait a couple days and see if someone tells me to spry some bleach in there to fix it. LOL

Controllers run on smoke and they stop working when the smoke leaks out.

FSIP (one of the BGW site sponsors) might be able to re-manufacture it. http://www.fsip.biz/GolfCarts.html

FWIW: Solid state means it uses transistors rather than vacuum tubes. Some, but not all controllers are filled with a potting compound to make them water resistant.

Helirich · 09-16-2015, 07:18 PM

OK, so I removed the controller to send for rebuild to fsip. When I removed it I wrecked a little electrical thingy. It's about the size of a nickel with two small wires that bridged two of the terminals. Is this important? If it is, what is it called? I need to order it cause I broke off one wire right next to the plastic nickel.

cgtech · 09-16-2015, 11:55 PM

Its a MOV. Not super important.

Helirich · 09-17-2015, 09:30 AM

I found one for about 20$. I'll get that ordered. What does it do?

JohnnieB · 09-17-2015, 09:47 AM

Quote:

Originally Posted by Helirich

I found one for about 20$. I'll get that ordered. What does it do?

That is an outrageous price for a MOV (metal-oxide varistor). Less that $5 is about what they cost at electronic parts stores.

They are surge protectors.

Helirich · 10-08-2015, 02:25 PM

Ok, so I got the controller rebuilt by FSIP. I'm putting it back in and I at the part of plugging the three spade connectors on. I marked two of them with tape. One has a one on it and the other has a two on it. I guess the other is three. This was several weeks ago and of course, I don't know what I was thinking. I don't remember if the one starts at the front or back. I would think I would make the one at the front, but it would appear that they would route better starting at the back.

The leed with the one on it is separate. The two and three come out of the same wire sheeve. Does anyone know if the separate wire is at the front or back of the controller?

scottyb · 10-08-2015, 04:02 PM

Does this help?

Helirich · 10-08-2015, 05:04 PM

Quote:

Originally Posted by scottyb

Does this help?

Yes, thank you very much!!!

09-13-2015, 05:37 PM	#1
Helirich Gone Wild Join Date: Sep 2015 Posts: 572	Marithon jerking My Marithon was giving indications of dead batteries. (They are 7 years old) but I got a new cart project with new batteries. So it only has to last a few more weeks. So I was using it and it started jumping. Like turning on and off a couple times a second. It would jerk so hard, I thought it might hurt something. I towed it back to the shop. I found the rear right battery and the controller mount had tilted down. The bottom was all rusted out. I had fixed some rust years back, but this area was not bad. Now it is. Anyways I figured the throttle rod was not working proper because the whole controller was moving. I took it all apart and rebuilt the battery suports and mounted the controller good. Got it all back together and went to back out of the shop and it started going, but wouldn't stop when I let off the pedal. (The pedal came back up) So I switched it from reverse to forward. It stopped. Then when I pushed the pedal, it started jerking again. I also detected some smoke. I'm thinking of pulling the motor unless you guys point me somewhere else. This sucks because I want to work on my new cart. But I have to have a working cart for my wife before I tare into the new one.
Helirich Gone Wild Join Date: Sep 2015 Posts: 572

09-14-2015, 09:36 AM	#2
Helirich Gone Wild Join Date: Sep 2015 Posts: 572	Re: Marithon jerking Ok, today I jacked up the cart and turned on the key. There was immediately some popping sound and some smoke. The smoke came from the bottom of the controller. I looked underneath and taped on the bottom of the controller. The cap came off and smoke came out. I didn't realize that there was a cap on them. I thought it was all solid state. (Full of epoxie) In any case, would I be correct to assume it's shot? I mean, nobody works on them, do they? It's just a standard controller. So can't be worth much. I might pull it apart and take some pics. But I'll wait a couple days and see if someone tells me to spry some bleach in there to fix it. LOL
Helirich Gone Wild Join Date: Sep 2015 Posts: 572

09-16-2015, 07:18 PM	#4
Helirich Gone Wild Join Date: Sep 2015 Posts: 572	Re: Marithon jerking OK, so I removed the controller to send for rebuild to fsip. When I removed it I wrecked a little electrical thingy. It's about the size of a nickel with two small wires that bridged two of the terminals. Is this important? If it is, what is it called? I need to order it cause I broke off one wire right next to the plastic nickel.
Helirich Gone Wild Join Date: Sep 2015 Posts: 572

09-16-2015, 11:55 PM	#5
cgtech Over This Interview Is... Join Date: Jun 2012 Location: AZ Posts: 17,449	Re: Marithon jerking Its a MOV. Not super important.

09-17-2015, 09:30 AM	#6
Helirich Gone Wild Join Date: Sep 2015 Posts: 572	Re: Marithon jerking I found one for about 20$. I'll get that ordered. What does it do?
Helirich Gone Wild Join Date: Sep 2015 Posts: 572

Today
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10-08-2015, 02:25 PM	#8
Helirich Gone Wild Join Date: Sep 2015 Posts: 572	Re: Marithon jerking Ok, so I got the controller rebuilt by FSIP. I'm putting it back in and I at the part of plugging the three spade connectors on. I marked two of them with tape. One has a one on it and the other has a two on it. I guess the other is three. This was several weeks ago and of course, I don't know what I was thinking. I don't remember if the one starts at the front or back. I would think I would make the one at the front, but it would appear that they would route better starting at the back. The leed with the one on it is separate. The two and three come out of the same wire sheeve. Does anyone know if the separate wire is at the front or back of the controller?
Helirich Gone Wild Join Date: Sep 2015 Posts: 572

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