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Unread 12-09-2011, 03:56 PM   #11
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Default Re: Wire smoking.. Need HELP!!!

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Originally Posted by carnejm View Post
Would the Pre-charge Resistor being burnt up keep my cart from moving? Because there is no power getting to the motor.
I would say yes because it is in the solenoid circuit . . . but not "positive" about that answer not having experienced that dilemma . . .
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Unread 12-09-2011, 04:09 PM   #12
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Default Re: Wire smoking.. Need HELP!!!

If the precharge resistor is getting hot the controller is fried as well. Ive seen this happen several times now. check your tow/run switch as well as it is likely blown as well. New controller, precharge resistor and tow/run switch will have you back up and running.
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Unread 12-09-2011, 04:11 PM   #13
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Default Re: Wire smoking.. Need HELP!!!

I really hope you are wrong! How can I test them to really know?
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Unread 12-09-2011, 04:15 PM   #14
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Default Re: Wire smoking.. Need HELP!!!

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Originally Posted by carnejm View Post
I really hope you are wrong! How can I test them to really know?
Replace the resistor first as it is the cheapest . . . cross your fingers . . . test . . . buy 2 resistors, just in case . .
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Unread 12-09-2011, 04:20 PM   #15
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Default Re: Wire smoking.. Need HELP!!!

unfortunately, im pretty sure your controller is the issue. if you are brave you can reinstall the resistor and attempt to fuse the wires that attach to the tow run switch. use a 15 amp blade fuse. THIS WILL CAUSE A LARGE ARCING AT THE FUSE IF THE CONTROLLER IS BAD. your resistor should have a value labeled on it you can test with an ohmmeter, if no value read the stripes. they correspond to a resistance value
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Unread 12-09-2011, 04:27 PM   #16
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Default Re: Wire smoking.. Need HELP!!!

Have you givin it Chantex?
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Unread 12-09-2011, 04:28 PM   #17
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Default Re: Wire smoking.. Need HELP!!!

I am still not 100% convienced it is the pre charge resistor. If you look in my picture, one end goes into the power supply going to the soleniod, the other goes directly to the controller.

In the diagrams i find for this cart I see the pre charge resistor going back to the soleniod and not controller. Am I looking at this wrong?
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Unread 12-09-2011, 04:30 PM   #18
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Default Re: Wire smoking.. Need HELP!!!

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Have you givin it Chantex?
Huh?
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Unread 12-09-2011, 04:42 PM   #19
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Default Re: Wire smoking.. Need HELP!!!

resistor is not the problem, it is the symptom caused by the controller no longer being able to accept incoming voltage, therefore it overheats the resistor because the voltage no longer has anywhere to go. Its like turning on the water hose full blast and capping the end of the hose. the pressure builds up and springs a leak. in this case the leak is manifested as heat leaking out of an overworked resistor. you will still need to replace the resistor as overheating can change the resistance value of the resistor.
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Unread 12-09-2011, 04:43 PM   #20
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Default Re: Wire smoking.. Need HELP!!!

Quote:
Originally Posted by wesleycox View Post
unfortunately, im pretty sure your controller is the issue. if you are brave you can reinstall the resistor and attempt to fuse the wires that attach to the tow run switch. use a 15 amp blade fuse. THIS WILL CAUSE A LARGE ARCING AT THE FUSE IF THE CONTROLLER IS BAD. your resistor should have a value labeled on it you can test with an ohmmeter, if no value read the stripes. they correspond to a resistance value
MY money is with you ...it's the controller.

One one the members at my campground had exactly the same problem....
after he tried doing some electrical without first disconnecting the batts.
the PRE-Charge resistor was smoking (hot) . It turns out he killed the controller and i had to replace it. ( it was a curtis )

I cut open his controller just for kicks and i found quite a bit of burn and melt in it.
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