Ezgo Marathon Pictures

pjmia96

I am having a Little trouble following the Wire Diagram for my 1991 EZGO Marathon Electric. Could someone take some pictures of all the Wiring under the seat. Motor, Controller, Battery's, Solenoid, Forward/Reverse Switch, Key Switch, and Everything Else. I just want the Standard Stock 1991 EZGO Marathon Wiring. Just get Everything you can all different angles. Free For All.

Just Start Posting Pictures of the Wiring, Anyone can do It.

I'm sure my thread could help many Other People Too.


Thank You All,

Matt

BGW

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JohnnieB

I can't help you with pictures since I don't have a Marathon, but I have been reading schematics and wiring diagrams for over half a century, so I might be able to help you decipher it.

However, there appears to be three different drive system used in Marathons
* Resistor cart
* Controller cart with plug braking
* Controller cart without plug braking.

Which do you have?

How about posting the diagram that you're having trouble with, so we'll be on the same page?

pjmia96

This is My Diagram. It is a 1991 EZGO Marathon Electric. Stock, With a Curtis 1204-001 Controller.

http://img299.imageshack.us/img299/8...bb42d7cyi6.jpg

pggroves

Hope it helps.

Good luck...

Attached Files

Marathon_Schematic.pdf (77.5 KB, 20 views)

windfish

Hey Matt
I've got a 1990 EZGO Electric with the solid state speed control, same as yours appears to be (I'm using the same diagram with mine).
The box with the potentiometer and microswitch is currently out as I'm replacing it (part hopefully in by wednesday), but if you'd like I'm happy to take a few pictures. Or wait till wednesday-ish and everything should be back together.
Anything in particular?

pjmia96

Wow that's Nice of you. :) Could you take some of the motor Wires and where they Connect, and the key switch? and the F & R Switch wires. Basically anything you can get. It all helps.

This is Very Nice of you. Thank You Sooo Much. :)


Also, What was the reason you needed to replace your potentiometer? My cart goes about 2 MPH on flat ground and on hills. Seems faster in Reverse. Even on Brand new battery's it did this. Have you ever had this Problem?(No Power) Its either the potentiometer or Controller. Anyways,

Thanks,

Matt

JohnnieB

Matt,
Disconnect the two wires going to the Potbox from the controller and measure the resistance between the wires.
Keyswitch = OFF
F/R Switch = Either F or R

Pedal up should be about 50 Ohms or less
Pedal down should be about 4500 Ohms or so.

(Technically, a 1204 series controller starts passing current to motor at about 300 Ohms and is passing max available current at about 4400 Ohms.)

The resistance should increase smoothly, but that is hard to see on a Digital Ohmmeter unless you push pedal down very slowly.
If you have an old analog type Ohmmeter available, watch for the needle to jumping around instead of climbing steadily.

If the throttle Ohms out correctly, reconnect the wires to the controller and jack up the back of the cart so it won't move.

Connect DVM test leads to B+ and M- terminals on controller.
Press throttle pedal slowly.
You should get zero volts, or close to it when solenoid clicks.
You should get full battery pack voltage when pedal is fully depressed.

Of course, if the battery pack voltage is under 36V, the cart is going to be very slow.

windfish

First picture isn't very helpful, but it shows battery wiring and the hole where the Potentiometer Box goes, across from the solenoid. Yours is probably a flattop solenoid, they do the same thing. Might go back tomorrow and retake the first picture, marking the wires so its clear where they're going.
Second picture should be a little more useful.
For the keyswitch, one wire is attached to a battery's positive terminal and the other to one of the microswitches.

Not great shots, but hopefully a little help.
(also, it wasn't supposed to rain; else the cart would have been covered :c)





Anyways, I'm fairly sure my potentiometer is dead due to the fact that its not doing as JohnnieB said -- it won't move smoothly from 0 to 5k. For some reason its jumping from 0 to 7k, or just sticking at the high or low values. I'm able to go smoothly from 0 - 5k with another pot. I have, so its not my multimeter lagging.
I picked this cart up dead, but it supposedly ran fine before it died. So I'm replacing the parts I think are dead and hoping it'll live again (and really hoping that controller isn't dead).

Best of luck on yours

pjmia96

Big Help

Thanks,

Matt