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Unread 02-18-2015, 12:19 PM   #51
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Default Re: Problems during solid state conversion

This diagram shows the only wires needed to make the system operate
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Unread 02-18-2015, 12:48 PM   #52
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Default Re: Problems during solid state conversion

Well I have run it now with resistor on, both on a jack with the brake as drag, and about 13 feet back and forth in my garage and it is still running 45 minutes later. Resistor is warm to the touch but not as much as it was before i took it off and reinstalled. Can't get it out on the road due to weather conditions, but dont want to move forward putting it all back together until i can be sure its reliable. I'll keep running it however i can though. I'll try to upload some pics of the whole setup.
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Unread 02-18-2015, 01:16 PM   #53
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Default Re: Problems during solid state conversion

That schematic looks as simple as you can get Scotty.

ecaldwell78, good to here it is working. You mentioned last time when it dropped out was after you got to a stop sign. This leaves me believe the circuit according to scotty's schematic is having trouble or intermittent issues is when you let go the go pedal and press it to go again. So that circuit from the key switch, pot/micro switch to the small wire going to the solenoid is where the problem exist. If it fails again after coming to a stop then you need to go through that part thoroughly and check your connections. One thing I see right off is you have three wires going to that small terminal on the solenoid. That could be the cause right there, it is very difficult to get that connection tight . Use a deep socket and make sure it is tight (be careful not to break though). If not there, then consider the Key switch connection & last the pot/micro switch connections.

If it does continue work well congrats, finally got it figured out.
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Unread 02-18-2015, 01:50 PM   #54
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Default Re: Problems during solid state conversion

Since messing around with the pre-charge resistor made the cart work before, I looked closely to what could have been affected by working on that area.

Looking at a close-up of the solenoid big post where you are getting power for the key switch, it appears the small gauge red wire terminal may not be making good contact.

it seems the washer and nut are putting pressure on the blue heat shrinking sleeve and not making good connection with the terminal itself.
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Unread 02-18-2015, 01:59 PM   #55
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Default Re: Problems during solid state conversion

Good eye Sergio! I'll go out right now and trim it back as some insurance. I need to run it for a few minutes anyway to make sure it still drives around the shop.
And Scooterman, the only wires on that cart that I haven't replaced are the two small gauge wires from the key switch. Kinda wishing i would've, but just want this part to be done! On a side note, i don't think i mentioned the one little "tweak" i made while messing with the resistor. the micro on the pot didn't always let the solenoid click and i really didn't think it was a big deal since all i had to do was goose the throttle and let off fast. But i was an annoyance so i ever so slightly bent that micro arm so it would be proper every time. Again, don't think it matters, but figured i would put it out there for the sake of full disclosure!
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Unread 02-18-2015, 02:56 PM   #56
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Default Re: Problems during solid state conversion

You might to give that resistor a hard look again to see if there is any movement of the leads in the crimp connections. "Not as warm as before" makes me wonder. When I installed my Super Duty solenoid, I had to add to the lead of the diode or resister ( can't remember which) because the body of the solenoid was so big (or the leads where so short). It would be easy to loosen the crimp while wrenching it down.

When you can make a real test ride you'll know all the de-bugging was worth it because the grin on your face will make your jaw sore.


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Unread 02-18-2015, 03:06 PM   #57
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Default Re: Problems during solid state conversion

you're right Tag, the solenoid body was really almost too big for the resistor. the crimp is solid, so much so that the ringlets got deformed a bit when i tightened the big terminal nuts! even though the temps are -15 and light snow, i may take it for a longer run when my son gets home just so i can have someone help to push should it stop again. i'm so ready to fly!
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Unread 02-18-2015, 03:09 PM   #58
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Default Re: Problems during solid state conversion

One issue I had with my conversion was the cable routing to the F&R switch. The cables need to move freely, the 2g cable is much stiffer and caused my F&R switch to loose contact. My F&R also had too much grease on it for the NM dust and became dirty immediately. I simply wiped the gritty grease off with a clean rag. The thin film of grease is plenty.

Make sure the spade terminals are nice and tight. I always tighten them before mating them with a pair of pliars.

Do Not buy crimping equipment from walmart or radio shack. At the very least get the ratcheting crimper from harbor freight and use 3m connectors.
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Unread 02-18-2015, 06:14 PM   #59
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Default Re: Problems during solid state conversion

Quote:
Originally Posted by ecaldwell78 View Post
Good eye Sergio! I'll go out right now and trim it back as some insurance. I need to run it for a few minutes anyway to make sure it still drives around the shop.
And Scooterman, the only wires on that cart that I haven't replaced are the two small gauge wires from the key switch. Kinda wishing i would've, but just want this part to be done! On a side note, i don't think i mentioned the one little "tweak" i made while messing with the resistor. the micro on the pot didn't always let the solenoid click and i really didn't think it was a big deal since all i had to do was goose the throttle and let off fast. But i was an annoyance so i ever so slightly bent that micro arm so it would be proper every time. Again, don't think it matters, but figured i would put it out there for the sake of full disclosure!
This could be the fix- all. If the throttle linkage was not letting the MS trigger properly or the MS trigger was misaligned then the solenoid operation would be effected. But, I thought we went thru all this basic stuff a few times already.
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