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



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Old 04-20-2012, 04:22 PM   #1
MikeStu
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Default Next troubleshooting step? Replaced old batteries.

I'm new to the golf cart world. I think it's a '92 (mfg code 111792, serial #702252). It had old batteries that would not hold a charge. I just replaced all of them and the cables. I downloaded the wiring diagram from the forum (thank you very much) and hooked everything up according to it. The reverse buzzer will come on, but the cart won't go.

Any suggestions on the next troubleshooting step? I'm thinking solenoid.
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Old 04-20-2012, 05:34 PM   #2
simple man
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Default Re: Next troubleshooting step? Replaced old batteries.

Before you do anything charge your new batteries! Make sure water just covers over the plates and let it charge until the charger shuts off.
Now, to your problem. Is this a resistor or controller cart? Do you hear the solenoid(s) click? If no clicking check your activation circuit. There will be some micro switches in that circuit. These are usually what goes bad on older carts. If the solenoid clicks it still may be bad. All of these items can be checked with a DMM or digital voltmeter.
Here's a link where you can download the manual for your cart. It will give you step by step troubleshooting procedures!
http://bennettgolfcars.ca/ezgo_manuals.php
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Old 04-20-2012, 05:39 PM   #3
JohnnieB
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Default Re: Next troubleshooting step? Replaced old batteries.

Quote:
Originally Posted by MikeStu View Post
I'm new to the golf cart world. I think it's a '92 (mfg code 111792, serial #702252). It had old batteries that would not hold a charge. I just replaced all of them and the cables. I downloaded the wiring diagram from the forum (thank you very much) and hooked everything up according to it. The reverse buzzer will come on, but the cart won't go.

Any suggestions on the next troubleshooting step? I'm thinking solenoid.
Here is what the serial # returns at the EZGO look up site.

Search Results

Model Year: 1992 Make/Model: Electric 4-wheel Marathon


As always, the first question is: What is the battery Pack voltage?
If it is less than 38.2V, your new batteries are sulfating as we speak.

Second question: Does the solenoid click?
If it doesn't, troubleshoot the KSI circuit (Key Switch and Interlock) also known as the solenoid activation circuit.
Here is a schematic with the KSI circuit traced out.

If it does, What is the voltage on the controller side main solenoid terminal when the pedal is pushed?

Let us know what you find and we'll go from there.
Attached Images
File Type: jpg Marathon - Controller Schematic. with KSI traced.JPG (78.6 KB, 0 views)
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Old 04-20-2012, 06:38 PM   #4
MikeStu
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Default Re: Next troubleshooting step? Replaced old batteries.

Thanks everyone for the quick replies.

I'll work through this (in between my daughter's softball tourney) over the weekend.
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Old 04-21-2012, 12:27 AM   #5
MikeStu
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Default Re: Next troubleshooting step? Replaced old batteries.

The batteries charged fully and the battery pack volt package is 39.4. The solenoid isn't clicking. I'll troubleshoot the solenoid activation some tomorrow.

I really appreciate the downloads and help.
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Old 04-21-2012, 04:26 AM   #6
yurtle
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Default Re: Next troubleshooting step? Replaced old batteries.

Check the reed switch that is connected to the charger outlet. It's what powers the rest of the activation circuit, and I had two fail on my 1998. Many people have reported similar failures. While the micro switches are also likely candidates, they are industrial products, and hold up fairly well.
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Old 04-21-2012, 05:26 AM   #7
JohnnieB
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Default Re: Next troubleshooting step? Replaced old batteries.

Quote:
Originally Posted by yurtle View Post
Check the reed switch that is connected to the charger outlet...............
It's a Marathon - No Reed switch
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Old 04-24-2012, 06:43 PM   #8
MikeStu
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Default Re: Next troubleshooting step? Replaced old batteries.

We're up and running!!! Thanks to everyone for the diagrams and the help.

I ended up replacing the solenoid and the igintion switch. $75 for both, not too bad.

The cart is Plain Jane at this point. Any suggestions on an easy/inexpensive upgrade for a newbie?
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Old 04-25-2012, 06:50 AM   #9
JohnnieB
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Default Re: Next troubleshooting step? Replaced old batteries.

Glad to hear you got it going.

"Golf Cart" and "Easy" and "Inexpensive" are mutually exclusive.

You've got new batteries and cables, so the next weakest link in the drive circuit is probably the F/R switch, or at least the cam.
http://www.cartsunlimited.net/F_R_Switch_Upgrades.html

Personally, I'd make it safe, efficient and reliable before adding "Bling".

You've got a "Classic", so you can either restore it to its original glory or turn it into a hot-rod.

Figure out what you want the end results to be and build towards that goal.

Be sure to take before, during and after pictures.
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