1997 TXT 36V - Battery Sparks When Being Hooked Up

[yler4cy]

I have to start off by saying I am new to electric carts. With that being said I picked up a 1997 EZGO TXT. I just got new batteries for it, they are measuring just over 37V when hooked up. When attaching the charging and battery meter cables nothing happens and the meter reads full. Once I try to hook up the cables from the solenoid it sparks.

Any help will be greatly appreciated. Even a wiring diagram so I can see if everything is hooked up right.

TIA

[Mooncarter]

Is the run/tow switch off?

[yler4cy]

I don't know if it is or isn't. I see the switch but no labeling on it to be able to tell differently. Suggestions?

[yler4cy]

Any more thoughts?

Hoping to get it figured out this weekend. I am going to go over the wiring diagram on here and hope that can assist as well.

[HarryT]

On Club Car Up is Run and Down is Tow. Not sure about EZ GO. Put the switch in the other position and touch a cable to the battery to see if it still sparks.
Harry

[meimk]

I seem to remember most EZGO's the "TOW" position is inward toward the batteries and the "RUN" is outward toward the passenger side of the cart. That's not an absolute though, on a 24 year old cart there's no telling who has done what to it over the years.

[binder49]

On my 95 medalist, run is down tow is up

[yler4cy]

So I tried it either way and it sparks, however if it is held on there it doesn't constantly spark. It just sparks when you initially put it on.

Once cable is tightened even with the switch inward (towards batteries) or outward the cart does nothing. I did notice that the battery meter dims significantly when hooked up. Something seems to be drawing a ton of power when hooked up.

[JohnnieB]

The DCS controller contains about 1.2 Farads of filter capacitors (see attached image), which have a bleeder network attached for safety reasons and if the controller has been disconnected from the battery for more than a minute or so, that huge amount of capacitance will be discharged and whatever is the last cable connected will spark considerably, if the diode/resistor assembly is installed.

The capacitors are also charged via Pin-10, so a significant spark can occur when certain of the control wires are connected.

[yler4cy]

All right so I think from all what I'm seeing everything seems to be okay I'm getting 37.3 volts to the solenoid. Now how do I diagnose as I'm not getting anything from there in regards to noise or rear wheels turning. I'd like to slowly eliminate stuff if possible so if you guys can point to me to any threads that have been created that'd be greatly appreciated.