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Electric EZGO Electric EZ GO Marathon, Medalist, TXT and RXV. |
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09-09-2020, 01:30 PM | #1 |
Not Yet Wild
Join Date: Sep 2020
Posts: 16
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36v Troubleshooting and Diagnostics
Hello experts, I am working on an unknown year Marathon 36v cart with a series motor. I was gifted the cart and it was in non running condition.
At this point, since it was left in the weather, I have: New solenoid New potentiometer Replaced the Curtis controller 1204-009 with a 1204m-4201 Batteries full charge reading at 38v. Dated 11/2018. Motor tested with 12v battery, spins freely/smoothly. When I press the go pedal the solenoid clicks but the motor does not spin. Any thoughts on what could be causing this? The only thing I think left is the FNR switch but that appears to be okay in that the solenoid is clicking. Maybe this ebay Curtis controller wasn't programmed properly or isn't working? It was supposed to be programmed to 0-5k by the seller. Any tips before I toss $400 of parts in the trash and buy an Alltrax controller? |
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09-09-2020, 02:15 PM | #2 |
Over This Interview Is...
Join Date: Jun 2012
Location: AZ
Posts: 17,449
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Re: 36v Troubleshooting and Diagnostics
"The solenoid clicks" only indicates the micro switches on the F&R work, does not show if the high amperage contacts in the F&R are good or not.
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09-09-2020, 02:29 PM | #3 |
Not Yet Wild
Join Date: Sep 2020
Posts: 16
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Re: 36v Troubleshooting and Diagnostics
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09-09-2020, 03:23 PM | #4 |
Not Yet Wild
Join Date: Sep 2020
Posts: 16
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Re: 36v Troubleshooting and Diagnostics
The FNR tested good for continuity as outlined in another thread, for both forward and reverse. The microswitches both tested good for continuity as well.
I am leaning more and more towards the new controller from Ebay. When checking voltage at the controller, it remains at full battery voltage (38v) regardless of how far I press on the go pedal. If I understand correctly, this seems to indicate the controller isn't responding like it should. Any wiring differences I may have overlooked on the new controller? Old model was a 1204-009 New model is a 1204m-4201 My research before buying this controller led me to believe this would be a viable replacement if programmed for my cart. The seller claims they programmed it to match my 0-5k ohm pot box. They didn't ask for any other details. |
09-09-2020, 03:46 PM | #5 |
Gone Wild
Join Date: Jul 2018
Location: Ramer, AL
Posts: 1,447
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Re: 36v Troubleshooting and Diagnostics
Have you check ALL connections (that you have not replaced) on this thing? If it has been sitting out in weather, I would undo every connection, clean and reconnect before I started spending big money on replacing controllers. Even if they look OK, I'd put a wrench on them. Takes time, but worth saving $400 or more. Be careful with motor connections, need 2 wrenches on them or you will be buying a new motor too.
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09-10-2020, 12:42 PM | #6 | |
Not Yet Wild
Join Date: Sep 2020
Posts: 16
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Re: 36v Troubleshooting and Diagnostics
Quote:
After looking at the Curtis 1204m manual it seems this is a direct replacement for my burnt up Curtis 1204 just programmable and with a couple extra terminals that don't need to be used. Does anyone know if there would be wiring differences between the 1204 and 1204m? |
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09-10-2020, 01:01 PM | #7 |
Gone Wild
Join Date: Jul 2018
Location: Ramer, AL
Posts: 1,447
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Re: 36v Troubleshooting and Diagnostics
Have you gone thru everything...look at this thread from ScottyB, very informative. You may want to do these checks before you start throwing money at it... https://www.buggiesgonewild.com/showthread.php?t=20729
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09-10-2020, 01:05 PM | #8 | |
Not Yet Wild
Join Date: Sep 2020
Posts: 16
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Re: 36v Troubleshooting and Diagnostics
Quote:
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09-10-2020, 07:12 PM | #9 |
Not Yet Wild
Join Date: Sep 2020
Posts: 20
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Re: 36v Troubleshooting and Diagnostics
Hi experts. I have 2008 club car that I upgraded control to 400amp. It is 36v. Everything was going good for couple months then I parked it the other night and next morning didn't work. I ordered new solenoid and replaced the old one because I didn't hear click. I took the resistors off of old solenoid but for some dumb reason I decided not to put them on the new solenoid. Well the cart worked for the whole night. We rode it around for a half hour or so then parked it. The next morning didn't work but I do hear the clicking from the solenoid. So were should I go from here? Did a ruin new solenoid?
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09-11-2020, 08:59 AM | #10 | |
Not Yet Wild
Join Date: Sep 2020
Posts: 16
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Re: 36v Troubleshooting and Diagnostics
Quote:
Battery pack voltage is 38.55 Battery side of solenoid is 38.55 Controller side of solenoid is 31.5 When I press the throttle I get full voltage through the solenoid. So I have a seven volt drop which seems to indicate a bad resistor. I did replace the solenoid but that didn't come with a new resistor so I used the old one. Would this bad resistor cause a completely dead cart? |
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