[Target70]

Originally Posted by WNDSRFR

HELP!

Does anybody have any idea what these wires do? The two conductor plug that goes nowhere is probably some sort test port or maybe a program port? I have no idea.
The other connector goes inside the car to the switch and the meter. Does anybody know which wires do what? Or am I completely on my own again? I think this is where my problem lies. Or God I hope it's not the controller.

I believe the other wires were for the alt charger which I believe was only ever necessary if you were tracking the kit. Basically it should just be a signal wire to tell the other charger when to start/stop charging the dump batteries.

As for it spooling up by itself, I could be wrong but I believe you said it comes on when the foot switch is unplugged. This is all my own speculation from here but that might mean that it is wired to trigger on a low signal / 0V on the signal wire or always on. The switch would then be a normally closed switch which would always be connecting the high signal (+5v or +12v) source to the signal wire thus turning the system off. When depressing the switch you would actually be opening the circuit giving the signal wire it's 0V and turning the system on. Again just my speculation. However if this is the case, you could check your harness to make sure it isn't frayed and/or grounding out against the body, or the switch or relay isn't sticking, and all the connections to make sure no pins have been pushed out of the connector blocks, or similar (not sure if your kit has a connector to the foot switch or if it is hardwired like mine). IMO those are the most likely source of failure, especially with all the tinkering you had to do recently. Following that would be the controllers internal circuitry, maybe check the fan wiring you recently replaced to make sure it isn't grounding against the case.