Wiring Hell...Help Plz

[branman1971]

1982 Marathon...Im trying to figure out the wiring and I have used 3 different methods and they all throw sparks at the battery terminals when I apply 36volts to the system. The setup I have now does not throw sparks and everything seems good ut there is no power to the motor. When I trace the wiring I find that there is 36v across the small terminals of the solenoid ut no juice across the large terminals. Also no juice at the key switch terminals. I altered a wiring diagram to show exactly how I have it wired. Ca yall take a look ad see if anything jumps out at you as wrong? Thanks

[branman1971]

The X's in the diagram show where I did not connect that component.

[branman1971]

Update: So something told me to try reverse ad the darn thing started running, in reverse. It runs slow in reverse even with the sweeper on the "stop" post and it does accelerate when I press the gas pedal. Only way I can get it to stop running in reverse is to turn the key off. I know I have something wrong still.

[93yellowclubcar]

I just saw your post, I'd been hoping you didn't give up on your cart. You have movement! That means at least something is getting closer to being right. I wish I could help you on this, but I'm much better versed in the CC department, plus my EZGO is a newer setup. Just a wild guess, sounds like a F/R switch or maybe a microswitch problem. I feel sure someone will be along with some good help shortly though, I look forward to reading about when you're cruising around on it!

[branman1971]

Thanks 93...Actually I saw another thread where someone switched the S1 ad S2 contacts so I tried it and Bingo she works in Both directions. But she starts rolling as soon as I turn the key on if in gear. Oh and I already ran her down the driveway and Back and she was smooth and pretty quick too. But I gotta put it in neutral to stop the drive.

[cgtech]

The microswitch that controlls the main solenoid seems likely to be causing the "always runs" problem. Are the wires on the microswitch connected to the "COM" and "NC" terminals. And does the switch only allow power to pass through "com" and "nc" when the pedal is pressed, AND, only allow power to pass through the "com" and "no" when at rest. You should probably test the switch with your "ohm meter" before testing it powered up with your "volt meter". OF COURSE, test it with the rear jacked up so you dont add a new door to your garage.

[branman1971]

I think I fried the switch cause there is no change in current when the switch is opened and closed. It doesn't "click" anymore either. This must have happened during one of my faulty wiring experiments. Looks like I need a new switch... For starters.

[branman1971]

And yes it is hooked up to the common and normally closed circuit And there is continuity. There is no change though when I cycle the switch. And there is no continuity between common and normally open and it does not change with the switch open or closed. And it does not click like I said before. Is there a way to open the switches and see what's going on inside?

[yurtle]

Sounds like the MS on the accelerator switch is not opening. Do you hear the solenoid click when you turn on the key?

[branman1971]

I tore the switch apart MS3 and got it clicking and installed. Now the cart runs but only forward. I had to switch S1 and S2 cables cause i only had reverse but its running in forward now, really well too I might add. The solenoid does not click when I turn the key on but it does click when you press the pedal and the sweeper gets to the second power post. That's when I hear the solenoid click and the cart starts to roll.