92 36V Textron Marathon Series no go

hmhsdad · 07-29-2009, 07:09 PM

My neighbor just bought a 92 Ezgo Textron Marathon Series Serial # 677230 and Manuf Code C1992. I have two questions.
1st question from reading posts.

SERIES carts will have a shift lever like the dcs cart down by your legs, but it will NOT have a tow/run switch. Also the actual F&R switch is in the corner by the controller and there is linkage from it to the lever in the center.....

This cart has a shift lever behind the knees and I don't see a tow/run switch, however, I also do not see a linkage from the F&R switch to the controller. There are microswitches on the F&R Switch. Is this still a fleet(series)?

Things checked:
1. F&R microswitches have continuity.
2. Across battery pack is 36.5 volts.
3. Solenoid going to controller has 36.5 volts.
4. 36.5 Volts at motor from controller.
5. 250 ohm resistor at solenoid is continuous.
6. Solenoid de-energizes when gas pedal is released.

Any help getting it going will be much appreciated. I've read tons of posts, but none so far have helped me.

Andy4639 · 07-29-2009, 07:54 PM

You are correct in the findings. The older Series carts the F/R was on the backside of the lever, the newer ones they moved over to the passenger side for battery clearances. If it's a passenger side one then it's a 94-95 or newer cart if it's in the middle it's before 94.
There is no linkage to the controller of any cart. You mean the F/R handle linkage right!

Cart jacked up on stands. Key turned off check micro switch on pot box see if it's showing cotinuity when you activate it with the pedal. If so then take the two small spade connectors off the controller that are white and black and check for OHM's with your meter. Press gas pedal and watch the ohms to see it climbs up to 5000 or so steady and no jumping around. 36.5 volts on the batteries is a sign of needing a charge the pack is almost dead. A 1/2 volt and it's done. 36 volts is dead.

hmhsdad · 07-30-2009, 02:51 PM

The switch on the pot box has continuity. I pulled the white and black spade connectors off the controller and with the gas pedal depressed it held a steady 2632ohms. It did not read 5000 ohms as you said. What now?

Thanks for the help.

Fleck · 07-30-2009, 04:42 PM

If the readings on the pot box wires started at 0 and only went to 2600 OHM. Try diconnecting the linkage from the arm on the pot box. Retest. The linkage may not be giving full movement of the arm and my need to be adjusted.

hmhsdad · 07-30-2009, 06:18 PM

Not sure of what I was doing earlier but the black and white spaded wires are reading 5.99 kilo ohms and holding steady. What to check now?

Fleck · 07-30-2009, 06:28 PM

Does it move at all or make any sounds? Is the 5.99 reading constant or is that at WOT. I've been told not to run the pot box over 5.1 because the controller will shut down.

hmhsdad · 07-30-2009, 06:58 PM

Yes, it was a constant 5.99 kilo ohm. I don't know what a WOT is. It does not move and only sound is the solenoid pulling in.

Fleck · 07-30-2009, 07:17 PM

Sounds like you have a bad pot box. Does the arm on the side move with the throttle pedal linkage? The ohms Should read 0 with the throttle pedal at rest. The ohm reading should smoothly rise to about 5000 ohm at WOT (wide open throttle).

hmhsdad · 07-30-2009, 07:33 PM

The throttle linkage does move an arm on the side. It shows as open circuit when throttle is at rest. But when pressed to WOT it quickly moves to 5990 ohms. Whould this still prevent it from going? I don't understand how I have 36.6 volts at the motor and it still doesn't move or attempt to move.

Fleck · 07-31-2009, 07:28 PM

Seems like you know how to use a volt meter

. Have you got a wiring diagram and checked your wiring? You should be able to find one in the "Stickies" at the top of the page. Other than that ; I'm at a loss on what to tell you. Maybe one of the resident "Smart Guys" will chime in. Try PMing Andy4639. He chimed in once and he maybe able to help. I just read a post that he is back to work so his computer time is probably limited. Good luck and keep us posted.

07-29-2009, 07:09 PM	#1
hmhsdad Not Yet Wild Join Date: Jul 2009 Posts: 7	92 36V Textron Marathon Series no go My neighbor just bought a 92 Ezgo Textron Marathon Series Serial # 677230 and Manuf Code C1992. I have two questions. 1st question from reading posts. SERIES carts will have a shift lever like the dcs cart down by your legs, but it will NOT have a tow/run switch. Also the actual F&R switch is in the corner by the controller and there is linkage from it to the lever in the center..... This cart has a shift lever behind the knees and I don't see a tow/run switch, however, I also do not see a linkage from the F&R switch to the controller. There are microswitches on the F&R Switch. Is this still a fleet(series)? Things checked: 1. F&R microswitches have continuity. 2. Across battery pack is 36.5 volts. 3. Solenoid going to controller has 36.5 volts. 4. 36.5 Volts at motor from controller. 5. 250 ohm resistor at solenoid is continuous. 6. Solenoid de-energizes when gas pedal is released. Any help getting it going will be much appreciated. I've read tons of posts, but none so far have helped me.
hmhsdad Not Yet Wild Join Date: Jul 2009 Posts: 7

07-29-2009, 07:54 PM	#2
Andy4639 48/400/Alltrax HS motor Join Date: Jan 2007 Location: Liberty SC, Garden City SC Posts: 6,190	Re: 92 36V Textron Marathon Series no go You are correct in the findings. The older Series carts the F/R was on the backside of the lever, the newer ones they moved over to the passenger side for battery clearances. If it's a passenger side one then it's a 94-95 or newer cart if it's in the middle it's before 94. There is no linkage to the controller of any cart. You mean the F/R handle linkage right! Cart jacked up on stands. Key turned off check micro switch on pot box see if it's showing cotinuity when you activate it with the pedal. If so then take the two small spade connectors off the controller that are white and black and check for OHM's with your meter. Press gas pedal and watch the ohms to see it climbs up to 5000 or so steady and no jumping around. 36.5 volts on the batteries is a sign of needing a charge the pack is almost dead. A 1/2 volt and it's done. 36 volts is dead.

07-30-2009, 02:51 PM	#3
hmhsdad Not Yet Wild Join Date: Jul 2009 Posts: 7	Re: 92 36V Textron Marathon Series no go The switch on the pot box has continuity. I pulled the white and black spade connectors off the controller and with the gas pedal depressed it held a steady 2632ohms. It did not read 5000 ohms as you said. What now? Thanks for the help.
hmhsdad Not Yet Wild Join Date: Jul 2009 Posts: 7

07-30-2009, 04:42 PM	#4
Fleck Gone Crazy Join Date: Nov 2008 Location: Pine Hill NJ Posts: 560	Re: 92 36V Textron Marathon Series no go If the readings on the pot box wires started at 0 and only went to 2600 OHM. Try diconnecting the linkage from the arm on the pot box. Retest. The linkage may not be giving full movement of the arm and my need to be adjusted.

07-30-2009, 06:18 PM	#5
hmhsdad Not Yet Wild Join Date: Jul 2009 Posts: 7	Re: 92 36V Textron Marathon Series no go Not sure of what I was doing earlier but the black and white spaded wires are reading 5.99 kilo ohms and holding steady. What to check now?
hmhsdad Not Yet Wild Join Date: Jul 2009 Posts: 7

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07-30-2009, 06:28 PM	#6
Fleck Gone Crazy Join Date: Nov 2008 Location: Pine Hill NJ Posts: 560	Re: 92 36V Textron Marathon Series no go Does it move at all or make any sounds? Is the 5.99 reading constant or is that at WOT. I've been told not to run the pot box over 5.1 because the controller will shut down.

07-30-2009, 06:58 PM	#7
hmhsdad Not Yet Wild Join Date: Jul 2009 Posts: 7	Re: 92 36V Textron Marathon Series no go Yes, it was a constant 5.99 kilo ohm. I don't know what a WOT is. It does not move and only sound is the solenoid pulling in.
hmhsdad Not Yet Wild Join Date: Jul 2009 Posts: 7

07-30-2009, 07:17 PM	#8
Fleck Gone Crazy Join Date: Nov 2008 Location: Pine Hill NJ Posts: 560	Re: 92 36V Textron Marathon Series no go Sounds like you have a bad pot box. Does the arm on the side move with the throttle pedal linkage? The ohms Should read 0 with the throttle pedal at rest. The ohm reading should smoothly rise to about 5000 ohm at WOT (wide open throttle).

07-30-2009, 07:33 PM	#9
hmhsdad Not Yet Wild Join Date: Jul 2009 Posts: 7	Re: 92 36V Textron Marathon Series no go The throttle linkage does move an arm on the side. It shows as open circuit when throttle is at rest. But when pressed to WOT it quickly moves to 5990 ohms. Whould this still prevent it from going? I don't understand how I have 36.6 volts at the motor and it still doesn't move or attempt to move.
hmhsdad Not Yet Wild Join Date: Jul 2009 Posts: 7

07-31-2009, 07:28 PM	#10
Fleck Gone Crazy Join Date: Nov 2008 Location: Pine Hill NJ Posts: 560	Re: 92 36V Textron Marathon Series no go Seems like you know how to use a volt meter. Have you got a wiring diagram and checked your wiring? You should be able to find one in the "Stickies" at the top of the page. Other than that ; I'm at a loss on what to tell you. Maybe one of the resident "Smart Guys" will chime in. Try PMing Andy4639. He chimed in once and he maybe able to help. I just read a post that he is back to work so his computer time is probably limited. Good luck and keep us posted.

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