Melex 625E 1999 Won't move

[mike733]

Just picked it up not running but in decent shape Batteries were dead
Put 6 new Crown CR220's in it with new 1/0 cables on all batteries. Wired as per the diagram on the inner fender. when I make the last connection the backup beeper goes off. key is off and in neutral. Tried to move it forwarded or reverse but it just nudges. Could something be wired wrong or something other than the batteries be broken?
Thanks Mike

[mike733]

Ok I took out the shifter switch and cleaned it all up. One of the micro switches needed some adjustment. I rewired the motor with bigger cables and herd a crunching noise while tightening on of the bottom nuts on the motor. The stud moved and is now a little loose in the motor. Cart runs fine in forward(still on jack stands) but only a click when switched to reverse. Do you think I should pull the motor or is it something else wrong?

[BumbleBee]

Originally Posted by mike733

Ok I took out the shifter switch and cleaned it all up. One of the micro switches needed some adjustment. I rewired the motor with bigger cables and herd a crunching noise while tightening on of the bottom nuts on the motor. The stud moved and is now a little loose in the motor. Cart runs fine in forward(still on jack stands) but only a click when switched to reverse. Do you think I should pull the motor or is it something else wrong?

sounds like something inside the motor broke. i would pull it and see what the inside of the motor looks like

[scottyb]

I Don't think it is a motor problem. If the motor works in forward it should work in reverse. IS this a series drive system? Double check the F&R and it's micro switches.

[mike733]

I changed the insulator in the motor but still no reverse. It does not always go in forward, but if I back off the switch a little it will go. I did find or in the process of checking broke the wire on a resistor??? that connects the 2 lugs on the solenoid. It also looks a little burned. I will try to find a replacement. I did have the F/R switch out to try to clean and tighten. I believe the micro switches are working correctly. Any other ideas?
Thanks
Mike

[mike733]

What is a series drive system?

[scottyb]

Originally Posted by mike733

I changed the insulator in the motor but still no reverse. It does not always go in forward, but if I back off the switch a little it will go. I did find or in the process of checking broke the wire on a resistor??? that connects the 2 lugs on the solenoid. It also looks a little burned. I will try to find a replacement. I did have the F/R switch out to try to clean and tighten. I believe the micro switches are working correctly. Any other ideas?
Thanks
Mike

This may be the problem right here. Intermittent F&R contacts? Series is the type of drive system you have.

[mike733]

Can I repair the switch or does it need to be replaced?

[mike733]

Ok I got it. It was the switch. I took it out took it completely apart, cleaned and put it back together. Now it works. I think it wan not completely making contact. not enough spring pressure. Thank you Now I can start on the Mods. fab a Rear seat I might make a lift and paint or wrap.

Thank you for all your help.

I still don't know what the resister looking thing is that was jumped across the terminals on the solenoid. It is currently not connected.

[scottyb]

The resistor and diode need to be in place on any Solid state cart.