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



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Old 09-19-2012, 05:56 AM   #1
ccrockett
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Default Help with controller,solenoid & fnr switch on a marathon

I am new to the forum and wish I had found it years ago, better late than never I guess. I just got an alltrax 500 amp controller, upgraded solenoid resistor and diode plus a new fnr switch. I need help with the wiring since I got the wrong diagram from the vender I bought the parts from. I have reached out twice both in email and phone with no response yet.
First problem is the fnr switch has two micro switches sames as the old one but the old one had a double micro switch and the new one is only a single and I am not sure how to wire it up.
Second problem is how to wire the new controller since it is completely different from the old one. The oem had 3 plugs for smaller guage wire and 3 bus bar connections. The new one has 4 plugs for smaller guage wire and 3 bus bar connections.
I am also assuming the cables will be in the same order as oem but not 100% sure.
FYI this is a pot cart series system 36 volts.
All help is appreciated
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Old 09-19-2012, 08:29 AM   #2
scottyb
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Default Re: Help with controller,solenoid & fnr switch on a marathon

I am sure with the help of johnnieb and a few others here we can do for you what the vender you chose did not...... Don't be shy about letting others know who you bought hundreds of dollars of components from who that does not offer tech support or answer emails or phone calls.

It will help us to know exactly what year and which drive system your cart is. I'm assuming Series? I'm assuming Ezgo? And what Controller and solenoid do you have?

If you want to start with the F&R, we can. There is a universal HD F&R out there available at any vender. It is not as HD as it could be, nor is it as universal as needed. It will work in your cart. Assuming Marathon (you said pot cart. I'm assuming that potentiometer throttle input = a marathon) You may need to swap out the F&R pivot shaft for your original so the shifter handle will mount up.
On the 2 MS (micro switch) remove the jumper wire. You will only need to use the one on the drivers side to run the cart the other is used for the back up alarm = your choice.

Here is the basic diagram of your cart we need more info to proceed or provide a more relevant diagram. I will check back later
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File Type: jpg ezgo marathon controller cart.jpg (168.8 KB, 0 views)
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Old 09-19-2012, 11:43 AM   #3
JohnnieB
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Default Re: Help with controller,solenoid & fnr switch on a marathon

Quote:
Originally Posted by ccrockett View Post
.............
1. First problem is the fnr switch has two micro switches sames as the old one but the old one had a double micro switch and the new one is only a single and I am not sure how to wire it up.
2. Second problem is how to wire the new controller since it is completely different from the old one. The oem had 3 plugs for smaller guage wire and 3 bus bar connections. The new one has 4 plugs for smaller guage wire and 3 bus bar connections.
3. I am also assuming the cables will be in the same order as oem but not 100% sure.
1. I'm not sure which side MS-2 is physically located on, but it is the one whose NC contacts are closed when the F/R switch is in either F or R.
That is the only one that needs to be connected for cart to run. (One wire comes from Keyswitch and other wire goes to microswitch on throttle assembly.

The double microswitch on the original F/R served two purposes.
A. Changed the pot resistance from 0-5k in forward to 0-2.5K in reverse.
You can use the other microswitch on the new F/R to feed B+ to pin-4 on new controller for half speed reverse.
B. Turned on beeper when F/R was in R. If you want a reverse beeper, you can wire it through the other switch also, but be careful, the original beeper was a 6V unit.
(In newer carts, half speed reverse is done by the controller and the beeper is a 36V type, so both can be done with one microswitch)

2 & 3. Sounds like the original controller was a Curtis 1204 and the new controller is a Alltrax AXE 4855.
Here is a drawing of where the wires and cables connect to the Alltrax, but the pin labels are wrong for your cart.
Pin 1 is the Blue wire from the throttle microswitch
Pins 2&3 are the black and white wire from the throttle pot.
Pin 4 is the half speed reverse input. (Optional)
For the cables, the the labels are also mixed up a bit.
Connect the high current cables the same way they were on the original controller.
B+ to Solenoid main terminal and A1
M- to "C" on F/R switch
B- to B- on battery pack
Attached Images
File Type: gif AXE-Wire-Diagram.gif (37.1 KB, 0 views)
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Old 09-19-2012, 12:05 PM   #4
ab46501
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Default Re: Help with controller,solenoid & fnr switch on a marathon

I have an Alltrax on my Marathon. I am going off memory here and maybe someone else can clarify but of the 4 smaller pins the one you do not use is the 1/2 speed reverse. The 1204 Curtis was the OEM controller for this cart and it it only had 3 small pins. Two were for throttle and one was for the key switch.
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Old 09-19-2012, 01:47 PM   #5
ccrockett
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Default Re: Help with controller,solenoid & fnr switch on a marathon

Guys,
Thanks for the start and the help!!! My cart is a 93 ezgo series 36 volt marathon.

So for clarification use the wiring diagram for my cart that is standard for connecting the motor, controller and fnr connections (high volt) I will not be running a back up beeper. half speed reverse is not wanted as this is a hunting cart and I am running the torque setup including the torque motor. Sometimes the mud gets thick and I have to back out and the extra power would be a get help.

I am also going to wire the solenoid just like the factory since I already have the diodes and resistor in place.

JohnnieB you are correct in the Alltrax controller. That will help tons!!!
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Old 09-19-2012, 03:47 PM   #6
yurtle
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Default Re: Help with controller,solenoid & fnr switch on a marathon

Here's the 4855 wiring diagram.
Attached Files
File Type: pdf Doc100-043-B_DWG-AXE-EZGO-Wire-Dia.pdf (174.3 KB, 0 views)
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Old 09-19-2012, 06:31 PM   #7
ccrockett
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Default Re: Help with controller,solenoid & fnr switch on a marathon

Quote:
Originally Posted by yurtle View Post
Here's the 4855 wiring diagram.
I have this diagram and it is totally different than my factory wiring. What it shows for wiring the motor, fnr swtch, controller and solenoid is tons different than the way it ws wired from factory. However i do appreciate the help Plus my cart is a 93 not a 94.
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Old 09-19-2012, 10:50 PM   #8
ccrockett
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Default Re: Help with controller,solenoid & fnr switch on a marathon

Ok guys I look at the old controller and the new one. The old controller has 4 lugs (a2,b+,b-, m-) the new one has 3 lugs (b+, b-, m-) not sure how to run the Wires.
Motor connections look like S2 to d on fnr, s1 to b on the fnr, a1 to b+ on controller
B- to negative battery bank
M- to c on fnr
B+ to + on battery pack
Does a2 motor go directly to A on fnr switch?
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Old 09-20-2012, 05:09 AM   #9
JohnnieB
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Default Re: Help with controller,solenoid & fnr switch on a marathon

Quote:
Originally Posted by ccrockett View Post
Ok guys I look at the old controller and the new one. The old controller has 4 lugs (a2,b+,b-, m-) the new one has 3 lugs (b+, b-, m-) not sure how to run the Wires.
Motor connections look like S2 to d on fnr, s1 to b on the fnr, a1 to b+ on controller
B- to negative battery bank
M- to c on fnr
B+ to + on battery pack
Does a2 motor go directly to A on fnr switch?
B+ terminal on controller has 2 cables on it.
One to A1 on motor as you correctly said in the sentence starting with "Motor connections look..."
The other connects to the controller side main terminal of the Solenoid rather than + on battery pack.
(The Solenoid's battery side main terminal is what connects to + on battery pack)

Yes, A2 on motor goes directly to A on F/R switch.
If cable isn't long enough, bolt the two cables that were on the original controller's A2 terminal together an thoroughly wrap with electrical tape so the connection won't arc if it touches anything.

------------
Basically, the new controller is connected the same as the old controller except there is no A2 terminal on new controller and the connection between A2 on motor and A on F/R is made directly rather than having a tie point at the controller. Also, Pin-4 (1/2 speed reverse) isn't used.
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Old 09-22-2012, 12:50 PM   #10
ccrockett
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Default Re: Help with controller,solenoid & fnr switch on a marathon

First many many thanks to Johnnieb and Scottieb. With their help my cart is running like a beast!!!!
I bought my Alltrax controller and high amp solenoid from D&D motors, price was good but the service was poor. I called several times and emailed but only got one return phone call and he left a message. So I will not be doing anymore business with them.
I bought my new wires and hd fnr switch from buggies unlimited. I called there tech support for wiring the fnr micro switches. They tried to help but said they didn't understand my questions and told me to wait for the controller wiring diagram. I called back and said my oem switch had two micro switches and the new one didn't. The guy left me on hold for over 20 minutes and never came back. I have always had good service but when I really needed it I got none.

My cart is a 93 marathon series 36 volt cart. It has a 4:1torgue motor, 500 amp alltrax controller, hd solenoid, hd fnr switch,4awg wires, 25" tires and wheels from a bad boy buggie filled with slime, it also has a jakes 6" lift. I trimmed the fenders to create extra clearance for the tires. this thing is designed to haul a trailer around the deer lease. Testing this morning it is pulling the wheels off the ground and doing burnouts.

Once again thanks for the help from everyone!!!!
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