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Old 07-22-2014, 10:18 AM   #1
PaConstable
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Join Date: Jun 2014
Posts: 15
Default Need help with installation of the F&R upgrade kit

Guys, I'm a bit lost. I bought the F&R upgrade kit from Golf Cart Care in Ohio. The diagrams are purely schematics with no labeling of components and my schematic skills are limited. Here's where I am now.....

I believe I have the solenoids wired correctly. When I hit the switch, they do click, but nothing happens at the starter/generator. My thoughts are at the microswitch. I have posted also the two sheets included with the components. To me, they are as clear as mud. They are going to post sideways and I apologize. that's how they scanned, but they still should be readable, minus the shoe prints.
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File Type: pdf ignition conversion2.pdf (241.1 KB, 0 views)
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Old 07-22-2014, 12:05 PM   #2
73eldo
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Harley Davidson
 
Join Date: Jul 2014
Location: St. Paul Minneapolis MN USA
Posts: 522
Default Re: Need help with installation of the F&R upgrade kit

Were the originals that fuzzy? If so that is how he is saving money using the lowest rez scan / copy possible.

I agree that its not a very well written procedure. For the guy who 'invented' this you would think he could have done a better job. Too bad there is really nothing to invent. Its a pretty simple circuit using fairly standard components that have been around about as long as electric motors have been around. The trick is getting good quality components at a reasonable price and then making a complete kit with well written instructions.

The first document is meant to show you more or less the existing cart with the old switch removed and only part of the new stuff installed. Its sort of telling you which of the small wires go on the new switch.

The second one is showing how to hook up the new solenoids. Seems to me the kit should include the 'jumpers'. Maybe another place this guy is saving money? The A1, A2, F2 are the terminals on the starter gen and should be marked on the gen itself. The E1 and E2 are to the new key.

Does that help?
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Old 07-22-2014, 12:11 PM   #3
73eldo
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Default Re: Need help with installation of the F&R upgrade kit

Looking again he says to make sure the diodes inline with a1 and a2 are in good shape with the bands pointing to the gen? That bit does not make sense. Diodes with bands are going to be fairly small, maybe 5 amps tops so those would not be inline between the solenoids and generator. There could be way more than 5 amps flowing there when starting, likely even more when charging so that does not make sense. Small diodes would be used more in the 'small wire' side of things.

I will have to try and draw this all out and wrap by brain around it, guessing his diagram works but its just not clear and easy to screw up.
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Old 07-25-2014, 02:35 PM   #4
PaConstable
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Default Re: Need help with installation of the F&R upgrade kit

Thanks. So far, I have the solenoids wired up what I do believe is correctly. The problem seems to be at the other end. They do click on, but nothing happens. I went strictly by his chart and actually disconnected everything and did it a second time to make sure that I did not make any mistakes.

First, I identified the cables by using the stampings on the generator and using an ohmmeter to identify the correct cables to keep from cross circuiting anything.

I agree that he did try to cheapen the kit by not including anything but the switch and solenoids, but that's business for you. I made jumpers cheaply by using a length of heavy gauge cable and connectors. I also replaced the connectors at the existing cables with good heavy duty ones that fit the solenoid lugs.

The diodes are at the A1 and A2 lines and connect to the generator at those lugs, per the way they were before.

When I switch on the key and engage the microswitch in F, there's no power at the generator. Both A1 & A2 show power when it's switched to R. That can't be right. And, again, no movement from the S/G. No smell of anything burning, so I take that as a good sign, at least of not causing any shorts.

At this point, I'm completely frustrated. I did call him and talked for a couple minutes, but it bore no fruit. To take the cart out to him to have him complete the install would cost me around the better part of a half tank of gas each way and $40/hour for him to work on it, money I just can't afford right now. I thought it would be the smart thing to replace the bad original switch with a better configuration, but now I have regrets and a DOA cart that I need to get rolling again.

I really hope you or someone else comes up with a solution real soon. If you do come up with anything, I can give you a phone number, fax number, e-mail address or if it comes down to it, I actually am going to be in Mankato on the 1st for a week, as I see you are from the Minneapolis area, not real far away. Still, I'd really like to have it done before we leave.
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Old 07-25-2014, 02:56 PM   #5
PaConstable
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Default Re: Need help with installation of the F&R upgrade kit

And here's a couple if photos to show that I'm trying to do it correctly. The one with the S/G, you'll see a jumper cable. That is supplying the ground that was stated in the instructions was needed at that lug of the generator. I didn't want to do a permanent one until I knew it was correct. I'm not convinced it is. Actually, I'm not convinced anything is correct at this point.

The red & brown wires at the bottom of the solenoid picture are for the headlights, so disregard them. The wire with the diode connected inline isn't plugged into anything. The white than becoming orange wire is going to the microswitch. Blue and yellow ones at the top are E1 and E2 switch wires.
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File Type: jpg IMG_2838.jpg (123.6 KB, 0 views)
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