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Unread 10-22-2015, 03:35 PM   #41
Not Yet Wild
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Default Re: No go... again

Hey Sergio,
I see it now its not forward power its a forward connection, A1 is the reverse connection, that being said its narrowed down to the f/r switch, white cable, A2 cable, S2 cable (all have continuity) how do you test that switch?
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Unread 10-22-2015, 04:37 PM   #42
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Default Re: No go... again

place probes as seen

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Unread 10-22-2015, 04:49 PM   #43
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Default Re: No go... again

When the FNR is in forward:
You should have +36v on the white cable at passenger side solenoid big post.
When the FNR is in Reverse:
You should get +18v on motor terminal A1.

Keep the FNR in reverse.

If You measure the voltage from that copper buss bar connecting all of the solenoids big posts to pack negative, you should have 0v.

As soon as You press the pedal and the first solenoid closes (driver's side), the voltage should rise to close to +18v.

If it does not, the first solenoid is not closing.
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Unread 10-22-2015, 07:00 PM   #44
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Default Re: No go... again

the switch tested 36v, 18v, the bus bar was all over the place as high 76, pressing pedal it was 17+ almost 18v.
anybody have the connections for the switch, based on Crashes diagram my pos. bat. is on 3rd term. ,2nd term. is on 18v rev., bat. pos. is S1 and 36v is on 3rd term.
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Unread 10-22-2015, 07:01 PM   #45
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Default Re: No go... again

Sorry Sergio forgot to check solenoid and motor.
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Unread 10-22-2015, 09:55 PM   #46
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Default Re: No go... again

The attached picture is how the FNR should be wired.

The white cable #5 goes to the big post on the passenger side solenoid.

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Unread 10-22-2015, 10:02 PM   #47
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Default Re: No go... again

Okay that's how its wired, Thank You Sergio
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Unread 10-23-2015, 12:56 PM   #48
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Default Re: No go... again

Forward 36v, Reverse 18v

Review:
1. All voltage tested proper
2. Motor tested good
3. All cables have continuity
4. F/R switch tested good
5. Speed controller voltage tested good and pressed pedal 1st solenoid engages
6. Pedal pressed I can feel all solenoids engaging
???????????????????????????????????????????
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Unread 10-23-2015, 01:50 PM   #49
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Default Re: No go... again

The resistor type cart is a very simple design that does not depend on any electronics to operate, you just need a continuous circuit from pack positive to pack negative for it to work.

Lets try this approach (I am including the FNR picture again for reference):

Disconnect the pack negative cable from the battery, leave any other wires still connected to the pack negative.

Turn the key switch ON

Put the FNR in Forward

Press the pedal and make sure you hear all solenoids engaging.

In the above scenario, the current will flow as follows (using conventional current flow notation for troubleshoot purposes)

Pack Positive -> FNR -> Solenoid on Passenger side -> Copper bus bar -> Solenoid on Drivers side -> Motor A2 -> Motor A1 -> FNR -> Motor S1 -> Motor S2 -> Pack Negative.


Set your meter to DC volts (either auto or 200v scale)

Put meter negative probe on pack negative battery post and keep it there during the entire test procedure.

Press the Pedal all the way down and keep it there during the entire test procedure.

1) Place meter positive probe on disconnected cable coming from S2.
You should read close to pack voltage if everything is working.
Proceed to next step if no voltage reading.
2) Place meter positive probe on motor terminal S2.
If You read close to pack voltage, that cable from pack negative to motor terminal S2 is BAD.
Proceed to next step if no voltage reading.
3) Place meter positive probe on motor terminal S1.
If You read close to pack voltage, the motor Field coil is BAD.
Proceed to next step if no voltage reading.
4) Place meter positive probe on FNR terminal S1.
If You read close to pack voltage, that cable from motor terminal S1 to FNR is BAD.
Proceed to next step if no voltage reading.
5) Place meter positive probe on FNR terminal A1.
If You read close to pack voltage, the FNR is BAD.
Proceed to next step if no voltage reading.
6) Place meter positive probe on motor terminal A1.
If You read close to pack voltage, the cable from FNR to motor terminal A1 is BAD.
Proceed to next step if no voltage reading.
7) Place meter positive probe on motor terminal A2.
If You read close to pack voltage, the motor armature/commutator is BAD.
Proceed to next step if no voltage reading.
8) Place meter positive probe on driver side solenoid where the cable from motor terminal A2 is connected.
If You read close to pack voltage, that cable from motor terminal A2 to solenoid is BAD.
Proceed to next step if no voltage reading.
9) Place meter positive probe on copper buss bar that is connected to ALL solenoids big posts.
If You read close to pack voltage, the drivers side solenoid is BAD.
Proceed to next step if no voltage reading.
10) Place meter positive probe on passenger side solenoid big post where white cable going to FNR is connected.
If You read close to pack voltage, definitely that passenger side solenoid and possible more solenoids are BAD.
Proceed to next step if no voltage reading.
11) Place meter positive probe on FNR terminal #5
If You read close to pack voltage the cable from passenger side solenoid to FNR is BAD
Proceed to next step if no voltage reading.
12) Place meter positive probe on FNR terminal +36v.
If You read close to pack voltage the FNR is BAD.
Proceed to next step if no voltage reading.
13) Place meter positive probe on pack positive battery post.
If You read close to pack voltage that cable from FNR to pack positive is BAD.
Proceed to next step if no voltage reading.
14) Your meter is either bad or not connected to pack negative.
repeat tests

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Unread 10-23-2015, 02:05 PM   #50
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Default Re: No go... again

Wow,
Sergio that took a lot of effort, really appreciate it. I got a few errands to run back at 4or 5, see what I can get done before dark. good thing I got a laptop. lol
Thank You for your help!!!
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