EZGO Marathon - Wiring is Screwed Up - Self Accelerates, Resistors Glow Red

[srobertson88]

Alright so, I deleted my other post, as people sort of just stop responding. I think I was giving too much irrelevant information. Trying again. Getting a bit frustrated – any help really is appreciated.

History. Summary = Was working fine, I disconnected everything and put it back together, now problems started, indicating I hooked something up wrong.
Had cart for 1 month and it was working fine.
Then, even though I had been using maybe an hour or two before, the batteries drained completely.
Not knowing the charger had to see a baseline pulse, I resorted to hooking up charging circuits in ways that didn’t seem to work, and may have pushed a bunch of energy to the wrong area.
Thinking there might be a short or something, I disconnected all the wires, clipped and replaced the connectors. I used new wire in a few spots using wire that was slightly thicker.
I took apart the FNR Switch box, cleaned it up, put it back. This was a pain, could have damaged the microswitch things, fumbled a lot trying to get the metal circle thing lined up right.
New key and new key ignition switch.
There were wires bundled and routed to the front and back bumper; along the route these wires went into a fuse box looking thing. To eliminate variables, and because there were no lights etc. on the other end of these wires, I removed them. Fuse box is empty. Someone said there may have needed to be something plugged in there, something to do about reducing the amount of power or something.
Anyway, finally I read on this site how to jump start to activate the charger, and it charged overnight.
The next morning, I give the cart a try, and sure enough it is moving as expected for about 20 – 30 seconds.
(Please note: no sparks or pops during the event)

Present issues. Summary = Sparks, Popping, Arcing. Self acceleration after go pedal is activated. Battery 6 has 3 wires on NEG, 1 wire on POS despite the wiring diagram indicating 2 on each. Verified this is the way it came and had worked fine for a month. I’m getting a scary beeping noise when screwing around with Battery 6. Horn is not connected.

I noticed though that it was sort of accelerating by itself. Didn’t think much of it.
The cart has been operating for less than 1 minute at this point and is now parked with the key on.
Smoke alerted me to the resistors which were cherry red. Key off, everything cooled down.
Tried it all again and the same issue would occur however now there was a loud pop, a pretty big spark, one time I swear a small flame whenever I would turn the key on. I believe I saw electronical arcing of about 3” occur at one point. All seemed to be coming from the Battery 6 / Controller box area.
At this point I referenced a wiring diagram (of the main wiring, not of the controller box wiring) and found that everything seems to be the same, except on Battery 6 I have 3 wires going to the NEG and 1 wire going to the POS. In the diagram, it shows 2 going to the NEG and 2 going to the POS.
When I attempt to take the small wire from NEG to POS, lots of sparks.
I am now getting loud beeping noises whenever I get the 3rd man wire close to the casing of Battery 6 or when I touch it to the POS terminal.

What I think Might Be Wrong
The 4 wires on Battery 6 that conflict with the wiring diagram.. they were like that when I got it. I’m thinking whatever issue that would normally cause was offset by him changing a second part of the wiring setup. It’s got to be in an area that I didn’t have good pictures of because everything else is hooked up exactly the same. Thus, I’ve got something wrong with how I reconnected the wires in the controller box. I can’t find a wiring diagram for the controller box. Also, I’m not sure if it should be hooked up how the diagram says because it does not take into account balancing the wiring issue on Battery 6.

Yes I’ve cleaned the wiper board. There is a click from the Solenoid when I turn the key. I’ve tested the individual batteries and they are fine. Have not checked Battery 6 recently.. the beeping has me avoiding it.
I can drive it, F or R, just fine but the resistors turn cherry red after 15 seconds.


Pictures

Attached


Bout to just let this thing run me over. Please help!! Thanks