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Electric EZGO Electric EZ GO Marathon, Medalist, TXT and RXV. |
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08-21-2019, 09:05 PM | #11 | |
Not Yet Wild
Join Date: Aug 2019
Posts: 13
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Re: 1994 Medalist, ITS Issue I need help with
Quote:
The phantom voltage did indeed disappear, after eliminating the pedal box connector. Now, a new issue- several times this afternoon, the cart wouldn't go right away. When I pressed on the pedal, the solenoid would engage, then wait two or so seconds, and then begin moving. I was a fire contolman in the USN once upon a time, and my experience with DC wants to say there's a slightly bad connection That's arcing itself together somewhere. But that could be totally wrong, and I should note that I haven't found any smoking guns or flashing signs. Does this sound like an ITS going bad? I ohmed out the cables running to the pedal box today, while vigorously wiggling the harnesses, and never lost connection. |
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08-21-2019, 09:17 PM | #12 |
Techno-Nerd
Join Date: Jun 2011
Location: West Virginia
Posts: 19,654
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Re: 1994 Medalist, ITS Issue I need help with
A lot of weird things have been cured by cleaning connections. (Air Force communications stuff then medical equipment.)
Bad connections typical cause heat, anything getting hot? When it doesn't move immediately, try wiggling direction selector lever. |
08-21-2019, 09:39 PM | #13 | |
Not Yet Wild
Join Date: Aug 2019
Posts: 13
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Re: 1994 Medalist, ITS Issue I need help with
Quote:
I keep going back the the ITS. Could it be motor brushes? When I had the controller bypassed, it never hesitated. I've been looking for motor brushes online, and can't find a part number for the brushes or motor. |
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08-22-2019, 11:16 AM | #14 |
Techno-Nerd
Join Date: Jun 2011
Location: West Virginia
Posts: 19,654
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Re: 1994 Medalist, ITS Issue I need help with
The controller doesn't power up until there is battery pack voltage on the red wire, so the 1 or 2 second delay could be the controller is slow powering up or the red wire is slow getting the needed voltage to power up the controller.
The pedal switch is the final link in getting voltage on the red wire and EZGO uses the NC contacts to pass the voltage, so you might have a gummed up microswitch causing the delay. The NC contacts are closed by an itty-bitty spring, so it doesn't take much to make it unreliable. Check the voltage on the red wire. Does tt appear instantly when pedal is pushed or is there a delay? Here is a parts manual that includes a '94 Medalist |
08-23-2019, 08:35 AM | #15 | |
Not Yet Wild
Join Date: Aug 2019
Posts: 13
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Re: 1994 Medalist, ITS Issue I need help with
Quote:
Ran great for probably two minutes. Stopped, and wouldn't go. It now has around 15 seconds before it starts going, after you pedal down. This is highly repeatable. Once underway, you can adjust speed as normal. Once stopped, it will not go again without pedal activation for around fifteen seconds. Then it jerks forward and goes. Voltage hits the red wire instantly upon pedal down. We have two extra controllers at our disposal. Both of the extra controllers are also behaving the same way. Reading all of these stories about how many problems people have with these, it's amazing they are still in business. |
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08-23-2019, 10:37 AM | #16 | |
Techno-Nerd
Join Date: Jun 2011
Location: West Virginia
Posts: 19,654
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Re: 1994 Medalist, ITS Issue I need help with
Quote:
If not, I'd move the red wire that powers up the controller from the solenoid coil terminal to the switched side of the keyswitch so the controller would power up when direction was selected and key was on. The pedal switch would still activate the solenoid, so safety isn't compromised. |
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08-24-2019, 06:25 PM | #17 | |
Not Yet Wild
Join Date: Aug 2019
Posts: 13
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Re: 1994 Medalist, ITS Issue I need help with
Quote:
this morning i went out and attached a test lead to the remote turn on lead of the controller (red control wire), and sent it straight to the battery pack. just wanted to test out the theory, not leaving it this way. the problem changed in a measurable way. it still starts out of the cart shed fine, and will run until you let off the pedal and come to a stop. once you let off of the pedal fully, it will not move. as long as you keep some voltage going thru the controller, it will keep responding. let off fully, it will coast to a stop and will not move. yesterday while it was doing this, it took several seconds of pedal press before it would start moving. today, it was very brief. so the issue did change. which leads me to believe there is some sort of overload protection built into the 1206 controller. it acts like something is overloading the controller, and causing it to reset/shutdown/protect mode briefly. keeping a constant wake signal to the controller seems to have reduced the "reboot" time, for lack of a better word. i have searched for schematics for this controller and haven't found much. however, having a bit of a background in mosfets and pulsed DC, i have never seen a successful design that did not use some form of protection. input, output, or internal circuit, i have no idea. |
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08-25-2019, 11:53 AM | #18 |
Techno-Nerd
Join Date: Jun 2011
Location: West Virginia
Posts: 19,654
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Re: 1994 Medalist, ITS Issue I need help with
I haven't been able to find a schematic or block diagram for a Curtis 1206 controller, but attached is a block diagram for a 1204/1205 controllers that were used in EZGO series drive carts prior to the introduction of the ITS throttle system. Versions of the 1204/1205 with ITS were also used in higher powered EZGO series carts after the 275A 1206 came out.
I doubt if Curtis reinvented the wheel entirely when the designed the 1206, so I suspect it is much the same from the block diagram aspect except for the throttle circuit. Also attached a 1204/5 manual. |
08-28-2019, 07:36 PM | #19 |
Not Yet Wild
Join Date: Aug 2019
Posts: 13
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Re: 1994 Medalist, ITS Issue I need help with
It was the controller, problem solved.
The original, the one from a local friend, and one I purchased thru Golframa reman. Found an FSIP reman and installed it, no more issues. Golframa were terrible to deal with, by the way. I had to get eBay involved to get my money back. |
08-29-2019, 10:35 AM | #20 | |
Techno-Nerd
Join Date: Jun 2011
Location: West Virginia
Posts: 19,654
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Re: 1994 Medalist, ITS Issue I need help with
Quote:
With luck like that, I wouldn't be buying any lottery tickets in the foreseeable future. |
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