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Electric EZGO Electric EZ GO Marathon, Medalist, TXT and RXV. |
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08-09-2014, 08:48 AM | #1 |
Not Yet Wild
Join Date: Jul 2014
Location: Houston, TX
Posts: 44
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Upgraded Contr / Solenoid / FR - HUGE SPARK! HELP
Like the title says, I upgraded my cart with the Cartsunlimited package 485 (Alltrax SPM 48500 controller, HD Solenoid) and changed the cables to 2 ga cables, and upgraded to the HD FR switch.
I followed the directions on the packages to the T. I first changed out the FR Switch and Cables, then tested. Everything worked fine. Then I changed out the controller and Solenoid. Took pictures, made note of what number cable was on what post on the old controller and solenoid, made recordings telling me what went where. I reconnected them just like they were. When I went to reconnect the battery pack with the positive in the 1st battery everything still ok. Then I went to reconnect cable 7 from B- on controller to the neg terminal on the last battery and POW! It looked like I was trying to weld!!! Any ideas on what could have happened? I double and triple checked everything. Any ideas on what I'm missing? |
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08-09-2014, 08:54 AM | #2 |
Happy Carting
Join Date: Dec 2007
Location: Southern California
Posts: 73,419
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Re: Upgraded Contr / Solenoid / FR - HUGE SPARK! HELP
Something is not connected correctly. Can you post pics of all the wiring? And cabling so we can see what goes where....
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08-09-2014, 09:04 AM | #3 |
Not Yet Wild
Join Date: Jul 2014
Location: Houston, TX
Posts: 44
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Re: Upgraded Contr / Solenoid / FR - HUGE SPARK! HELP
Here's what I have. If you need more, I can try to get some better ones.
Before 2014-08-08 21.07.38.jpg After 2014-08-09 08.49.34.jpg |
08-09-2014, 09:16 AM | #4 |
Happy Carting
Join Date: Dec 2007
Location: Southern California
Posts: 73,419
|
Re: Upgraded Contr / Solenoid / FR - HUGE SPARK! HELP
The fuse and the solenoid look to be correct... triple check that Controller B- is connecting to battery main (-)
Where does the M- wire go? |
08-09-2014, 09:27 AM | #5 |
Not Yet Wild
Join Date: Jul 2014
Location: Houston, TX
Posts: 44
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Re: Upgraded Contr / Solenoid / FR - HUGE SPARK! HELP
Just checked it B- on controller goes to neg terminal on battery pack.
Attachment 107872 Attachment 107871 Attachment 107870 M- on Controller goes to A2 on Motor 2014-08-09 09.19.01.jpg 2014-08-09 09.19.27.jpg 2014-08-09 09.19.36.jpg |
08-09-2014, 09:29 AM | #6 |
Not Yet Wild
Join Date: Jul 2014
Location: Houston, TX
Posts: 44
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Re: Upgraded Contr / Solenoid / FR - HUGE SPARK! HELP
not sure what happened to the 1st set of pics. Here they are again. I think...
2014-08-09 09.18.00.jpg 2014-08-09 09.18.12.jpg 2014-08-09 09.18.21.jpg |
08-09-2014, 09:37 AM | #7 |
Happy Carting
Join Date: Dec 2007
Location: Southern California
Posts: 73,419
|
Re: Upgraded Contr / Solenoid / FR - HUGE SPARK! HELP
Probably something simple. leme think, can you recheck all the cable routes?
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08-09-2014, 09:41 AM | #8 |
Not Yet Wild
Join Date: Jul 2014
Location: Houston, TX
Posts: 44
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Re: Upgraded Contr / Solenoid / FR - HUGE SPARK! HELP
I'll go back and check them and write down what goes where.
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08-09-2014, 09:44 AM | #9 |
Happy Carting
Join Date: Dec 2007
Location: Southern California
Posts: 73,419
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Re: Upgraded Contr / Solenoid / FR - HUGE SPARK! HELP
I see that pic of the cable end now ....... you have a dead short someplace. Check each cable -#1 thru 8 one at a time. Make sure no exposed ends are touching any metal other than the terminal they are attached to .
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08-09-2014, 10:00 AM | #10 |
Not Yet Wild
Join Date: Jul 2014
Location: Houston, TX
Posts: 44
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Re: Upgraded Contr / Solenoid / FR - HUGE SPARK! HELP
Cable 1 - Rt side of Solenoid next to black wires, runs to + terminal on Battery pack.
Cable 2 - Left side of solenoid to B+ on controller Cable 3 - B+ on controller to bottom of F/R switch Cable 4 - Top of F/R switch to A1 on motor Cable 5 - S1 on motor to Driver side connection on F/R switch Cable 6 - connects A2on motor to M- on controller Cable 7 - B- on Controller to Neg terminal on battery pack. Cable 8 - Passender side F/R switch to S2 on motor 2 red wires from wiring harness connected to the controller go to the left side small terminal on solenoid. Silver side of diode on left side connected to red wires. 1 Black wire from wiring harness to Rt side solenoid. 1 Independent black wire connects rt side of solenoid to B- on the controller. Are there any connections I'm missing or that I didn't note here? |
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