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Unread 06-20-2019, 02:14 PM   #1651
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Default Re: 03 EZGO won't move in forward or reverse

03 EZGO won't move in forward or reverse



Quote:
Originally Posted by Bamarep View Post
Thanks, I'll definitely check that. Simple stuff first, right?
It's a series. It's all simple. Hopefully not expensive.

In case you have limited time on week days, do ScottyB's test, then here's another fast test for throttle signal:

Ezgo throttle testing

Click on the attached thumbnails on the link.

I know you said you had the manuals, but if your computer's slow, here's chapter E, troubleshooting.
Attached Files
File Type: pdf Chapter E.pdf (17.33 MB, 0 views)
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Unread 06-24-2019, 06:09 AM   #1652
72 volts!
 
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Talking Re: 1989 Marathon EZGO electric wire identification

Hope this may help you out some. You can save the pictures and then blow them up to see better.
As you know the schematics are not that great when it comes to details. This should help with that.
Attached Images
File Type: png resistor write up.png (190.8 KB, 0 views)
File Type: jpg resistor write up22.jpg (202.6 KB, 0 views)
File Type: png resistor write up3.png (168.7 KB, 0 views)
File Type: jpg resistor write up4.jpg (124.2 KB, 0 views)
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Unread 06-24-2019, 07:20 PM   #1653
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Default Re: switch in reverse moves cart forward

switch in reverse moves cart forward



The diode on the F/R switch assembly tells me it is an early DCS drive. (See attached photo)

The DCS controller defaults to forward and is told to do reverse by applying battery voltage on Pin-4 (orange wire). (See attached schematic)

Check for voltage on Pin-4 when F/R is in Reverse. If it is, the controller is likely to be bad.

If it is, replace it with an Alltrax XCT48400DCS. The DCS controller (Curtis 1206SX) was a failed design.

Also, the F/R switch assembly can be replace with DPDT/center off (On-Off-ON) toggle switch. (See attached drawing)
Attached Images
File Type: jpg Early DCS F-R with diode-.jpg (195.2 KB, 0 views)
File Type: jpg Wiring Diagram - Early DCS - Diode.JPG (111.8 KB, 0 views)
File Type: jpg Replace Early Type DCS FNR with DPDT switch.jpg (41.8 KB, 0 views)
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Unread 06-25-2019, 12:12 PM   #1654
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Default

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Unread 06-25-2019, 10:04 PM   #1655
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Default Re: stalls going up hill

Quote:
Originally Posted by dabadas View Post
I have a 2003 ezgo txt I just purchased. Took it to a ezgo dealer and they installed new batteries and solenoid. fully charged it runs great has good speed but going semi steep hills it stalls to a stop. it has 23 inch tires and im sure motor and controller are stock. what could it be? Thanks
The cart is designed to run 18" tall tires and the 23" tall tires are costing you 22% of the torque available from a stock motor and controller.

It is also designed for a max of a 14 incline with 18" tires, the max incline will be less with 23" tires.

Using the attached grade conversion chart, how steep is a semi-steep hill?

---------------
The good news is your cart can most likely be upgraded to climb steep hills.

What type drive system does it have?
If there is a F/R lever by the driver's knee, it is a series drive, if the F/R is a rocker switch next to keyswitch on dash, it is a sepex (PDS) drive.
Attached Images
File Type: jpg EZGO - Stock Incline.jpg (94.4 KB, 0 views)
File Type: jpg Grade conversion chart.jpg (167.3 KB, 0 views)
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Unread 06-28-2019, 12:34 PM   #1656
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Default Re: Old E-Z-Go Golf Cart

All the info is here, you just have to look



Cart around would be able to help you better. I think this is the same thing you have

In one of these videos, he puts the piston in backwards, but he does corrects it





http://www.buggiesgonewild.com/attac...-ezgo-2-1-.pdf


http://www.youtube.com/watch?v=9B5BrLQlKko



http://www.youtube.com/watch?v=Zv4RwNAH57c


http://www.youtube.com/watch?v=1vTHHOvDyVw
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Unread 06-28-2019, 01:13 PM   #1657
Test before replacing
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Default Re: Old E-Z-Go Golf Cart

Old E-Z-Go Golf Cart


EZGO GAS MARATHON




This is part of their history. 1980 was a transition year from internal starter to external. They also changed the ignition, but I don't know exactly when. I'm hoping you don't have points.

"They later moved the company to Augusta Georgia where it remains to this day. All of the golf carts produced ran on batteries until 1971 when they introduced a 175cc model 17-CES 1PG two cycle Robin version. They used this four bolt head Robin engine made by Fugi Heavy Industries until 1975. In 1976 they came out with a six head bolt model EC25-DS 244cc two stroke Robin engine also made by Fugi. This engine also had an internal starter/generator that was kept until mid 1980. In mid 1980 they introduced the external Hitachi starter/generator. This model EC25-2PG engine was used until 1988. In 1989 until 1993 they used the model EC25-3PG 244cc two stroke Robin engine. In 1991 they came out with their first four stroke engine , a 295 cc, 9 hp one which was replaced by a 350 cc four cycle in 1996. In 1997 Textron bought out Cushman and continues to manufacture Cushman industrial vehicles as well as their E-Z-GO line of golf carts and industrial vehicles."
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Unread 06-30-2019, 05:27 AM   #1658
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Unread 06-30-2019, 04:13 PM   #1659
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Default Re: Cart got left in the rain....

Cart got left in the rain....



Attached is a drawing showing the voltage paths through a stock PDS controller. The voltage paths through an XCT is almost the same. The difference is the next point the voltage goes to after the Run/Tow switch is the F/R switch AND the Keyswitch.
Attached Images
File Type: jpg Voltage paths through PDS controller.jpg (138.9 KB, 0 views)
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Unread 07-03-2019, 10:38 AM   #1660
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Default Re: Re-gearing gas ezgo axle

Re-gearing gas ezgo axle


EZGO GAS REAR END







Here is a manual for the Fuji rear diff.
Attached Files
File Type: pdf Fuji Differential.pdf (6.34 MB, 0 views)
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