90 ezgo getting 36 volt reading between hot to switch and load side

zroadrage

I have a 90 model ezgo. It was working fine last weekend. This weekend when I got on it and turned it on nothing happened. After looking the load side of switch to controls wire was broken/burnt off. Easy fix? But when I went to reattach it it blew Sparks out. I checked with meter and from line side of switch to load side it reads 38v. How is that? I checked for skinned place on wires and found nothing. I took wires loose trying to track down the issue and i'm just stumped. Please any advise or help would be great.

BGW

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JohnnieB

Welcome to BGW!

Is it a Resistor drive or a Electronic Speed Control drive?

Where exactly is is the switch with the wire burnt off, physically located?

The 38V means your 36V battery pack is about 95% charged.
A fully charged 36V battery pack reads 38.2V and if a 36V battery pack reads 36V, it is less than 50% charged.

zroadrage

the switch is the main key switch that turns on cart. the reading is actually 38.2v. it has resistor drive i think. it is a square box that looks like a power inverter. thanks for the reply.

zroadrage

i dont understand why the load side of switch is reading negative. it goes to controls and limit switches. shouldnt it be no reading between these wires?

scottyb

That is right, you have a short someplace. If there is a diode on the solenoid small posts this may have failed open? Seemed like you were on the right track trying to see where the short is coming from

simple man

Check your wiring harness everywhere it passes through the body and frame. The wire insulation tends to get rubbed through from vibration and just old age.

zroadrage

If I remove the diode will should it clear short if that's the problem?

zroadrage

The solenoid is new but could that be issue?

JohnnieB

Remove both the diode and resistor for the time being.
They are not needed for troubleshooting and getting the cart running, but should be reinstalled for normal operation.
(Their purpose is to reduce arcing on some of the contacts and prolong their service life.)

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Installing the diode backwards, occasionally happens when a solenoid is replaced.

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I'm guessing, but it sounds like you have a Controller cart, so here is a schematic with the solenoid activation circuit highlighted.

Attached Images

Marathon - Controller Schematic. with KSI traced.JPG (78.6 KB, 0 views)

zroadrage

That's the right diagram for sure! If I remove the orange wire from the solenoid then that would clear the short if that is the problem correct?