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Electric EZGO Electric EZ GO Marathon, Medalist, TXT and RXV.



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Old 04-06-2015, 08:03 PM   #1
scalpem15
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Default 92 marathon wont go - controller?

92 ezgo marathon controller cart stopped this weekend as I backed out of garage. Took off a full charge, hit the gas and it jerked in reverse but died immediately. Solenoid clicks but nothing else. I have taken the following measurements/ tests:

- pack voltage 38.4v
- 6.4v on each battery
- pot box went from 0 ohms with pedal up to 6500 ohms with pedal fully depressed - gradual climb with pedal
- pack voltage at battery side of solenoid with key on
- pack voltage at controller side of solenoid with pedal down (? below)
- pack voltage at b- and m- terminals on controller with pedal pressed enough to engage solenoid; voltage does not budge as pedal is fully depressed

? on solenoid from above - I measure about 27v on controller side of solenoid with pedal up and solenoid not engaged - is this normal/residual power stored in controller? I have not disconnected the wire from solenoid to controller.

I welcome any ideas and suggestions. JohnnieB this is a continuation of thread earlier today.

Thanks to all!
Brandon
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Old 04-07-2015, 05:28 PM   #2
scalpem15
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Default Re: 92 marathon wont go - controller?

Somebody? Anybody? ��
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Old 04-07-2015, 05:33 PM   #3
scottyb
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Default Re: 92 marathon wont go - controller?

Yes normal, you are reading pack voltage thru the resistor. I assume solenoid clicks and controller side of solenoid voltage rises to pack reading then.
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Old 04-07-2015, 06:06 PM   #4
scalpem15
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Default Re: 92 marathon wont go - controller?

Thanks Scottyb. Yes that is correct. Any ideas on a culprit based on what I posted above?
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Old 04-07-2015, 06:29 PM   #5
jjance
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Default Re: 92 marathon wont go - controller?

With the solenoid engaged do you read the same voltage on both large terminals of the solenoid?
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Old 04-07-2015, 06:34 PM   #6
scalpem15
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Default Re: 92 marathon wont go - controller?

Jjance, yes 38.4v on both
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Old 04-07-2015, 06:43 PM   #7
scottyb
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Default Re: 92 marathon wont go - controller?

Some more checks you can make


CHECKING CONTROLLER INPUT
Connect (-) probe to B- terminal. Connect (+) probe to B+ terminal.
The reading should indicate approx. 0 volts with the resistor REMOVED and the pedal not pressed in the last 15-30 minutes.
Slowly depress accelerator pedal until the solenoid engages.
The reading should show the battery pack voltage. If the voltage is at or near battery voltage, the cart is in forward gear, and the motor is not turning, then the problem lies in the forward/reverse switch, the high amperage wiring, the speed controller, or the motor.


CHECKING CONTROLLER OUTPUT Connect (-) probe to controller M- and (+) lead to controller B-
With the key on and the cart in forward gear, press the pedal just far enough to hear the solenoid engage. You should read pack voltage between and M- and B-. Now continue to press the pedal down and watch the meter. The reading should gradually decrease to near 0 volts. If the input test was good and the ITS readings are correct and this test does not perform as described above then the controller has failed.
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Old 04-07-2015, 06:58 PM   #8
jjance
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Default Re: 92 marathon wont go - controller?

Quote:
yes 38.4v on both
That tells me the solonoid is good.
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Old 04-07-2015, 07:03 PM   #9
scalpem15
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Default Re: 92 marathon wont go - controller?

Will try those thanks Scottyb. Should the resistor be removed for output test too? What does ITS mean? Thanks again!
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Old 04-07-2015, 08:56 PM   #10
scalpem15
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Default Re: 92 marathon wont go - controller?

Ok. Controller input test revealed 0v with pedal up and full pack voltage once solenoid is engaged. Nothing from the motor.
Output test gave me full pack voltage when solenoid engaged and remained there when pedal was fully depressed. Couple of runs even gave me 16v at solenoid click and no change as pedal was floored - not sure if those were just bad reads but either way it wouldn't appear the controller passed the test.

Time for a new controller or anything else to try at this point?

Thanks again for the help guys!
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