EZGO 36 volt controller wiring issue

[dannyferris]

I am looking for wiring troubleshooting for my ezgo marathon electric. New batteries are in but it looks like some solenoid issues may be at play here. I'm not sure about the value of the diodes and how they hook up. It is a 1993 model

[JohnnieB]

Welcome to BGW!

If you haven't already, new batteries need to be fully charged before first use, and the properly broken in to obtain maximum storage capacity.
Here is how to do it:http://www.cartsunlimited.net/Batter...n_Methods.html

I believe the attached is a schematic for your cart, but I might be wrong.

With key on, F/R control in F or R, does the solenoid click when throttle pedal is pushed?

While troubleshooting, neither the diode across the solenoid coil, nor the resistor across the solenoid contacts have to be installed.
They can be installed after you get cart running.

[dannyferris]

I am attempting to wire my 1993 EZGO Marathon and am having issues with the curtis 1204 controller. Using thier trouble shooting guide, I have good battery voltage coming out of the solenoid until I connect the wire to the B+ terminal on the controller. The voltage drops to 16 volts as soon as it makes contact with the controller. I have changed controllers and am still experiencing this issue. Can anyone tell me what the problem might be? I have tested the motor by bypassing the controller and wiring straight to the battery and it runs fine.

[rib33024]

Welcome to BGW


need to start with the batteries, how old are they?? what is the pack volts after the battery pack/all 6 - 6volt batteries have been OFF the charger for 12 hours, at rest??, when is the last time it ran? and why is it not running now/what happen

[JohnnieB]

With the controller connected, what are the battery pack and individual battery voltages?

You are missing over 20V, so let's go looking for it.

[dannyferris]

I am using (3) 12 volt batteries for now just to get it running. They are brand new deep cycle and are fully charged. I have removed and tested all switches individually and they all are working fine. the only part that is bad is the 250 ohm resistor. I have ordered those but I dont believe they would cause this problem.

[dannyferris]

Also forgot to mention, when the motor is wired straight to the batteries it does run very strong

[dannyferris]

The cart was not running when I purchased it. The old couple I bought it from said it runs fine and just needed new batteries so I brought it home and started going through it from front to back, cleaning and inspecting EVERY part using the factory service manuals for both the cart and the curtis controller.

[dannyferris]

Thank you Johnnie B

[rib33024]

there's no need to start another thread about this problem, keeep it in one thread it will make it easier to fix your problem