Contactor not engageing properly

Solenoids · 05-05-2013, 09:07 AM

The cart is a Yamaha 2003 that was long ago converted to a series motor and setup. Today the setup is as follows: 48V, 850 amp controller, 1/0 power cabling, MZJ 400 for master contactor, SW 202 for FWD/RV contactor, ~ 10 hp GE Industrial motor converted by EMP for 2 mode cart operation.

About 10 days ago I noticed that the MZJ was only engaging or disengaging when I turned the key switch on or off. In the past it would engage or disengage when the key switch was turned and also when the accelerator was depressed.

While it runs fine, it worries me that there is a problem which could cause me damage.
For that matter the SW 202 F/R switch only engages when the key is turned on (although I can’t recall if that is the way the SW 202 always was).

Anyway, I’ve tried 3 things:
1. replaced the foot on/off (kill) switch
2. replaced the throttle sensor unit
3. I also checked the accelerator control to make sure the pedal was retracting all the way to the stop.

None of these actions fixed the engagement issue of the MZJ 400.

Any thoughts what could be causing this to work this way? Suggestions?

Lastly, should I be losing sleep over this problem? What might be the consequences of the MZJ only engaging/disengaging with the key?
You have helped me inthe past, thanks in advance. Jery

Andy4639 · 05-05-2013, 06:19 PM

Depending on the wiring it can do it either way. Now how it stopped doing it one way and started doing it another is something you need to figure out. As far as it being a problem no. Just that a safety feature is bypassed as in the gas pedal not having to be pushed for it to engage.

Now are you sure it wasn't the F/R contactor kicking in first when the key is turned on and it's in gear.

Solenoids · 05-05-2013, 07:04 PM

Thanks for your response. No, it was the master MZJ engaging when I pushed the accelerator down. And now when the key is turned on, the master engages and stays engaged until the key is turned off. And, since it changed on its own, it is probably a wire that is messed up, right?

Do you have a reference that shows how the kill, throttle and Master should be wired? Or an idea as to where I can find a diagram that would work for the 2003 Yamaha that has been converted to series?

This control wiring was set up 10 years ago by a dealer who is no longer in business and I am in the middle of the Nevada desert...and I believe it needs to be redone.

Thanks, again

Andy4639 · 05-05-2013, 08:00 PM

Well just to be honest I wired my like you describe it. Mine is turned on and off with the key. I'm not very well versed on the Yamaha's wiring schematics. May want to try the section on them and ask some one else.
U may want to check in here.

http://www.buggiesgonewild.com/electric-yamaha/

05-05-2013, 09:07 AM	#1
Solenoids Not Yet Wild Join Date: Jun 2012 Posts: 26	Contactor not engageing properly The cart is a Yamaha 2003 that was long ago converted to a series motor and setup. Today the setup is as follows: 48V, 850 amp controller, 1/0 power cabling, MZJ 400 for master contactor, SW 202 for FWD/RV contactor, ~ 10 hp GE Industrial motor converted by EMP for 2 mode cart operation. About 10 days ago I noticed that the MZJ was only engaging or disengaging when I turned the key switch on or off. In the past it would engage or disengage when the key switch was turned and also when the accelerator was depressed. While it runs fine, it worries me that there is a problem which could cause me damage. For that matter the SW 202 F/R switch only engages when the key is turned on (although I can’t recall if that is the way the SW 202 always was). Anyway, I’ve tried 3 things: 1. replaced the foot on/off (kill) switch 2. replaced the throttle sensor unit 3. I also checked the accelerator control to make sure the pedal was retracting all the way to the stop. None of these actions fixed the engagement issue of the MZJ 400. Any thoughts what could be causing this to work this way? Suggestions? Lastly, should I be losing sleep over this problem? What might be the consequences of the MZJ only engaging/disengaging with the key? You have helped me inthe past, thanks in advance. Jery
Solenoids Not Yet Wild Join Date: Jun 2012 Posts: 26

05-05-2013, 06:19 PM	#2
Andy4639 48/400/Alltrax HS motor Join Date: Jan 2007 Location: Liberty SC, Garden City SC Posts: 6,190	Re: Contactor not engageing properly Depending on the wiring it can do it either way. Now how it stopped doing it one way and started doing it another is something you need to figure out. As far as it being a problem no. Just that a safety feature is bypassed as in the gas pedal not having to be pushed for it to engage. Now are you sure it wasn't the F/R contactor kicking in first when the key is turned on and it's in gear.

05-05-2013, 07:04 PM	#3
Solenoids Not Yet Wild Join Date: Jun 2012 Posts: 26	Re: Contactor not engageing properly Thanks for your response. No, it was the master MZJ engaging when I pushed the accelerator down. And now when the key is turned on, the master engages and stays engaged until the key is turned off. And, since it changed on its own, it is probably a wire that is messed up, right? Do you have a reference that shows how the kill, throttle and Master should be wired? Or an idea as to where I can find a diagram that would work for the 2003 Yamaha that has been converted to series? This control wiring was set up 10 years ago by a dealer who is no longer in business and I am in the middle of the Nevada desert...and I believe it needs to be redone. Thanks, again
Solenoids Not Yet Wild Join Date: Jun 2012 Posts: 26

05-05-2013, 08:00 PM	#4
Andy4639 48/400/Alltrax HS motor Join Date: Jan 2007 Location: Liberty SC, Garden City SC Posts: 6,190	Re: Contactor not engageing properly Well just to be honest I wired my like you describe it. Mine is turned on and off with the key. I'm not very well versed on the Yamaha's wiring schematics. May want to try the section on them and ask some one else. U may want to check in here. http://www.buggiesgonewild.com/electric-yamaha/

Similar Threads
Thread	Forum
Questions on how to properly do 400 Amps.	Electric Club Car
How to properly adjust govenor on 96	Gas Club Car
How can I tell if my charger is working properly?	Electric EZGO
contactor wiring	Electric EZGO
Charger functioning properly?	Electric Club Car

Today
BGW	Sponsored Links __________________ This advertising will not be shown in this way to registered members. Register your free account today and become a member on Buggies Gone Wild Golf Cart Forum