1990 Marathon with ScottyB's conversion

[crackers450]

Hi All,
Today I replaced the solenoid 200amp HD, replaced both F & R wiring from rocker switch to sw202 contactor nothing wrong with the wire just extended slightly, yellow wire for reverse , orange wire for forward, replaced diode on solenoid, pulled cables off the motor tested motor runs OK using just 12v battery, probes from the DVM across B- & M- I get 19.8v, press accelerator till solenoid clicks I get full battery pack 38.2v, keep pedal going to full still have 38.2 v, I know that's not right as it should go back to 0v, also there is no click coming from the F/R contactor could this be the problem? brains trust, how do I test the sw202HD forward reverse contactor also how can I test the Alltrax 500amp controller to be able to see what expensive part I have to buy

[scottyb]

sw202 testing attached

[crackers450]

Thanks Scotty,
this morning I went to move the cart into the garage to work on some testing. pushed it in, jacked up the rear wheels hit the key selected F and the wheels began turning, selected R again wheels turning, tidied up some tools, put the seat back in, lowered the cart and away it went, it has run all day without skipping a beat, so what ever I had done seems to have fixed the problem, serviced the cart (grease & brake adjustment), repaired some holes in the cart cover where rats had chewed through the vinyl windows and canvas with clear gorilla tape, the only thing I can think of is that after I replaced the above items , solenoid, MS, 2 small electric wires, the cart's electrics must have reset itself
Cheers
Laurie

[DubK]

Nice update for the old cart. Never seen a marathon updated to the rocker switch style. I may need to do this as well as my fnr switch keeps giving me problems

[scottyb]

Originally Posted by DubK

Nice update for the old cart. Never seen a marathon updated to the rocker switch style. I may need to do this as well as my fnr switch keeps giving me problems

The reversing contactor install is a great update for any series Ezgo or Club Car.
This is an old kit here. I think The current Alltrax SR control is 2 generations after this AXE conversion. Showing good durability.

If you really want to modernize your Marathon read this thread > https://www.buggiesgonewild.com/showthread.php?t=184127

[crackers450]

Guys,
It's happened again after running no problems for 2 days, I went to move it back to it's parking spot and nothing, dvm between b- & m- 19v? press accelerator it climbs to 38.2v, led on 500amp Alltrax goes green then out then full green again, tested the batteries individually & get 6.3v on all, checked with a hydrometer and picked up 2 dead cells in battery 1 & 4 but they still showed 6.3v would the 2 dead cells be causing this stoppage , it,s got me stuffed

Laurie

[scottyb]

Originally Posted by crackers450

Guys,
It's happened again after running no problems for 2 days, I went to move it back to it's parking spot and nothing, dvm between b- & m- 19v? press accelerator it climbs to 38.2v, led on 500amp Alltrax goes green then out then full green again, tested the batteries individually & get 6.3v on all, checked with a hydrometer and picked up 2 dead cells in battery 1 & 4 but they still showed 6.3v would the 2 dead cells be causing this stoppage , it,s got me stuffed

Laurie

2 dead cells could be the problem. In any case they are a problem that needs to be addressed pronto.

[crackers450]

Thank Scotty,
I have a battery specialist coming down home to check properly, I am in the process of hooking up a 7th battery for 42 volts until I can afford the $2000 for the 48v upgrade, we'll see what happens
Cheers
Laurie

[crackers450]

Scotty,
It just stopped again and I get nothing, the LED goes green then goes out 1 flash, then goes solid green but no movement, I disconnected the pot wires to check the reading and it comes out at 6.1ohms and I get 3 red flashes from the controller (HPD? Throttle hasn't gone to zero during this power cycle ?) what does this mean please, could the pot be bad, I have purchased a replacement but it has 2 leads coming out instead of one so I have no idea which one to use, any help would be great
Thanks
Laurie

[crackers450]

OK now I have replaced the solenoid, diode, potentiometer & ms, new wiring, put the new pot in yesterday and it worked perfectly drove around for approx 1/2 hr, parked the cart up, put it on charge, this morning after 12hrs pack voltage 38.1v turned key on hit accelerator NOTHING but a solenoid click, led on controller goes green then out, then solid green, measured the ohms on the pot leads and get 5.0 Ohms, still nothing can, anyone help with other ideas?
Laurie