1989 EZGO resistor cart problem

[jtb51b]

OK, long and short-- bought a used cart, replaced the batteries and cables and while it was down had the lugs that the power wires connect to on the motor replaced. Electric motor shop did the work. Now, when I hook it back up I get a properly functioning forward but when I select reverse it arcs at the F-N-R switch. I have double checked the wiring and can't seem to find a mistake. I am using the wiring diagrams from the stickies. What could be going on here? The cart ran and drove fine before, just the batteries were very weak. Any ideas on where to start tracing this thing? I am going to check the FNR with an ohm meter with the batteries dico'd but I dont know what else to check..

Jason

[scottyb]

Is the F&R being intermittent? Can you wiggle the handle and make it arc or interrupt service while driving?

[jtb51b]

It did one time on the first ride. After that no, I just pulled the FNR down and it appears to be working correctly. It shifts the contacts as it should.. I did tighten the handle up a bit to make it functional after I had already taken it apart. Would a loose/faulty FNR cause arcing? It was arcing pretty badly, very scary with it being fully charged and in my basement. But, the ignition switch did stop the arcing so maybe its not as bad as I think..

I am putting the FNR switch back in now.. BTW the contacts on the FNR were slightly burned/melted on one set of the contacts.

Jason

[scottyb]

likely you found your problem....

CAUTION

Wet cell batteries produce hydrogen gas, it is very explosive. One spark in the gas is all it takes to blow the lid of a battery or 2.

[jtb51b]

I may have stumbled upon another problem.. Looking at the diagram I cannot tell where the wire on the micro switch (on the wiper board) opposite the solenoid is supposed to go. I assume it is a ground to let the solenoid come on only when the pedal is pressed but I don't know what sort of ground it is. From the diagram it looks like it runs to one of the other micro switches on the FNR control but my wire has a 5/16 ring terminal on the end like it has at one time been connected to a large wire lug.. Any thoughts?

The backup buzzer has not worked since new and I found the red wire cut as well.. The black wire which should go to the positive terminal of the first battery has not been connected as well.. I am unsure how this could work.. I wish I could find a clearer diagram on this thing.. Or someone who has one in correct form!

Thanks for the quick help, I will be working on it and looking back often!

Jason

[jtb51b]

Ok, I checked and checked and think I have this right.. Only problem is that I have continuity from a1 to s1 and from a2 to s2.. I would think I should never have 0 ohms from the a to the s.. But from the s to the s and from the a to the a I should? Whats correct?!??

JAson

[jtb51b]

Ok, best I can figure it that some how the motor shop swapped the one of the a's for one of the s's when re assembling the case. Is this possible? I had some issues on getting this thing fixed, the guy was not very dependable.. How can I establish which is a1 and which is s1 and so on? or would it matter?

Jason

[jtb51b]

Got it straight.. I pulled the motor and checked it out.. The motor shop had indeed swapped s1 and a2 as I suspected.. I'm just glad this thing didn't catch fire in my basement. This would have had a whole different ending to it.. Thanks for all the help. Might replace the resistors just for the heck of it but other than a little aesthetics work I think we are good! Ran it about 4 or 5 miles tonight and brought it home to give it a good long charge, it was still pulling good too...


Jason

[roady89]

If those terminals were inline perpendicular to the case then yes, its entirely possible to swap them.....takes a moron to do it but possible...or intentional.

[jtb51b]

Here is what it looks like, not my axle just a pic. The two on the right hand side were swapped. I dont know how that mistake could be made from a tech with 20 years of experience but it was! Either way the cart runs great now, used set of batts are holding up great.. I have to replace the timer in the charger as it does not progress through the hours to 0 but other than that it works.

Jason