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



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Unread 02-23-2014, 09:43 PM   #1
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Default Solenoid wiring question 1988 marathon

I am replacing wiring on my recently purchased 1988 Marathon. In looking at wiring diagrams some show a cable from the rear terminal of the solenoid (the same terminal where the cable powering the accelerator switch is connected) that goes from the solenoid to the #1 position on the accelerator. However, some wiring diagrams do not show this second cable on the solenoid, just the flexible one to the accelerator lever.

Which diagram is correct for my 1988 Marathon?

When I got the cart the wiring was in bad shape and there was an extra cable from the #1 accelerator bolt to the #1 bolt on the resistor coil - two cables doing the same apparent job. There was no cable from the solenoid to the #1 accelerator bolt. When I saw this second solenoid cable in one of the wiring diagrams I wondered if the former owner moved this "extra" cable from the solenoid to the resistor coil.

Any advice will be appreciated! Thanks!
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Unread 02-24-2014, 09:02 AM   #2
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Default Re: Solenoid wiring question 1988 marathon

My 89' had the wire. JohnnieB explained to me what this wire is for. He can probably correct the wrong parts of what I am about to say. The wire supplies an extra passage for the high amount of current the crosses the contacts. The edges of the contacts are the weakest points of the contacts. If there was not this extra wire, eventually the edges of the contacts would eventually be worn away from arcing.

With all of this being said, I took the wire off of mine. I was, and still am, having some arcing issues between my stationary and movable contacts. I was thinking this wire might be having something to do with it. I have not driven the cart much and haven't put the wire back. The short time I moved it around my shop, I was still having the issues.

All you need for the wire is a short piece of I'd say at least 6 gauge. I used a short battery cable when I replaced mine. I hope this helps. And JohnnieB, feel free to correct anything I said!!
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Unread 02-24-2014, 09:12 AM   #3
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Default Re: Solenoid wiring question 1988 marathon

There are wiring diagrams (Physical layout)and schematic diagrams (Electrical layout) floating around, but all I've seen have the #1 coil connection, the #1 contact on the wiper board and the wiper, all connected to one of the contact terminals on the solenoid.

The two cables can be physically attached at the solenoid terminal or the #1 terminal on the wiper board, but they are electrically the same point.

The purpose of the seemingly redundant cable is the reduce the arcing between the #1 contact and the wiper when the pedal is first pushed.
Without it, max current starts flowing before the wiper and first stationary contact are fully engage. The potential for arcing is less severe between the wiper and subsequent stationary contacts because the motor is already spinning.
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Unread 02-24-2014, 10:59 AM   #4
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Default Re: Solenoid wiring question 1988 marathon

I have a question to add to this. JohnnieB, correct me if I'm wrong, and I probably am. Can the wire from the first resistor go straight to the solenoid? This would bypass the wiper board for the first resistor and possibly get rid of the arcing issue I was having.
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Unread 02-24-2014, 12:20 PM   #5
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Default Re: Solenoid wiring question 1988 marathon

Quote:
Originally Posted by tculpepper View Post
I have a question to add to this. JohnnieB, correct me if I'm wrong, and I probably am. Can the wire from the first resistor go straight to the solenoid? This would bypass the wiper board for the first resistor and possibly get rid of the arcing issue I was having.
Yes, but you would still have to have a cable from the solenoid to the wiper arm or all you would have is the lowest speed.
In fact, it looks like you could wire from the solenoid output straight to any of the coil terminals and have a single speed cart.

When wired according to the schematic, there are three terminals tied together electrically with two cables. Any one of the three can be the one with two cables attached to it.

When those three terminals are tied together electrically, there should be little, if any, arcing on the first stationary contact, but every picture I've seen of a wiper board shows some arcing on it. I'm not sure why this is happening, but it appears to be.

That wiring arrangement doesn't do much anything for the other stationary contacts, so bad arcing on them may be a mechanical adjustment of some kind or another.
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Unread 07-15-2016, 03:02 PM   #6
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Default Re: Solenoid wiring question 1988 marathon

Old thread but have a question. The wire from solenoid to the wiper board attaches to #1 or to the first contact used ? The wiper board I have has 5 points and others I have seen have 4. So do I take the cable to the very bottom stud that's not connected to a resistor ?
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Unread 07-16-2016, 07:52 AM   #7
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Default Re: Solenoid wiring question 1988 marathon

Quote:
Originally Posted by ERV JR View Post
Old thread but have a question. The wire from solenoid to the wiper board attaches to #1 or to the first contact used ? The wiper board I have has 5 points and others I have seen have 4. So do I take the cable to the very bottom stud that's not connected to a resistor ?
The five contacts are labeled for the speed they produce, 0 through 4.

The "0" contact has no cables attached.

The attached schematic shows the cabling layout for the accelerator switch fairly well.
Attached Images
File Type: jpg Resistor cart - Schematic.JPG (87.4 KB, 0 views)
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Unread 07-16-2016, 12:57 PM   #8
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Default Re: Solenoid wiring question 1988 marathon

Ok thanks. I figured out why there 5 contacts and what the shunt/jumper from the solenoid dose. Now to go back and add the throttle micro switch that's has been removed. Rewire the ing. Switch and solenoid
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