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Unread 12-09-2011, 09:05 PM   #31
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Default Re: Wire smoking.. Need HELP!!!

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Originally Posted by golfcartthing View Post
its the controller. Send it in to fsip to get rebuilt. Seen this happen 100's of times.
fsip?
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Unread 12-09-2011, 09:14 PM   #32
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Default Re: Wire smoking.. Need HELP!!!

The precharge resistor supplies voltage to 2 large capacitors that are inside the controller. The precharge resistor will not keep the cart from running. You will get a large spark when you reconnect the batteries. What is happening is that the capacitors will suck as many amps as they can to charge up. The missing resistor provided a path with resistance (ohms) to slow the current flow into the caps. What you now have is a bad controller. Always remember to turn the key switch off, selector in neutral and tow/run switch in tow position when ANY wire is either connected or disconnected !!! Not following this procedure will kill some club cars, ALL EZ-GO, and Yamaha G-9 thru G22. I know, because being the boss, I have to eat the cost of the first controller a Tech kills... The rest come out of his salary. They tend to learn real fast when their money is involved. I install a lot of controllers that a hobbyist tried to fix. Been at this for a while and you are not the first one. Also 1 warning in my shop about rings, watches, and necklaces. The second time I catch them with any of the above, 2 days off without pay. This is not me being mean. OSHA has teeth and will use them. Also goes for rubber gloves and face shield when working around batteries. I have a brother that works on BMW and Audi cars in Greensboro. ! finger missing (fan belt and a red rag) equal 1 less finger. I worked flight line and flew in the backseat of f-4's during Vietnam for 2 years. Went by the rules and used safety equip. like it was a religion. I have all 10 fingers, 2 good eyes, and two good feet to get me around, and I can hear supertime even if she wispers. How many of you wear earplugs around these loud engines. Carbon monoxide detector on all 4 walls. 8 fire extinguishers. My insurance man loves me.
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Unread 12-09-2011, 09:21 PM   #33
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Default Re: Wire smoking.. Need HELP!!!

Thank you to everyone who posted on this thread. It was very informative for a newb like me!!!

For sure this was a lesson learned. I will not forget to kill the power again, I can assure you of that!

I believe I have isolated the issue to the controller. Now the question is, do I stick with the stock controler for $150 (off ebay). Or do I go ahead and upgrade it? If so, to what? I am going to be lifting this cart and using it for hunting. So torque is important.
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Unread 12-09-2011, 09:25 PM   #34
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Default Re: Wire smoking.. Need HELP!!!

Flight Systems Industrial Products. the remake controllers for all the golf cars, fork trucks, etc. or you can sent it to Controller Test Services, the offer a 450 amp upgrade for the IQ controller.
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Unread 12-09-2011, 10:12 PM   #35
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Default Re: Wire smoking.. Need HELP!!!

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Originally Posted by carnejm View Post
So I put the resistor back on, turn the cart to run, turned key on and pushed the gas pedal. It clicked, but didnt move. I take that as the soleniod is still good?

Almost immeadiatly the resistor started to smell burnt again so I quickly disconnected.

I believe I have ruled out the resistor and soleniod as the problem.

So it must be OBC, controller, or the motor.

The motor is problem not the issue since there is no power getting to it.

I have another few newbie questions:

1. If the cart is in "tow" mode , what should happen?
2. Is there a way to tell if the computer is still good? I plugged in the charger and it clicked, but it never started charging.
ok, this sounds like the solenoid to me...

even though you hear a click, that doesn't necessarily mean that the solenoid is functioning properly. if the circuit is asked to conduct current (ie. pressing the Go pedal) that current should will flow in the path of least resistance. ie: through the solenoid, not the resistor. if the resistor is instantly getting hot enough to smoke, i suspect current is not passing through the solenoid, but rather trying to pass though the resistor.

at this point, i would advise thoroughly testing the solenoid as your next step.

Quote:
Originally Posted by carnejm View Post
fsip?
Flight Systems Industrial Products (controller rehab service)

*note - this option would likely cost more than a factory pulled controller from PQ
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Unread 12-09-2011, 10:15 PM   #36
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Default Re: Wire smoking.. Need HELP!!!

Quote:
Originally Posted by carnejm View Post
I believe I have isolated the issue to the controller. Now the question is, do I stick with the stock controler for $150 (off ebay). Or do I go ahead and upgrade it? If so, to what? I am going to be lifting this cart and using it for hunting. So torque is important.
if it is indeed the controller and you plan on upgrading the cart, the sevcon is the best deal available.
-sj
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Unread 12-09-2011, 10:16 PM   #37
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Default Re: Wire smoking.. Need HELP!!!

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at this point, i would advise thoroughly testing the solenoid as your next step.
Is that easy to do? Where can I find instructions?
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Unread 12-10-2011, 12:52 AM   #38
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Default Re: Wire smoking.. Need HELP!!!

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Originally Posted by carnejm View Post
Is that easy to do? Where can I find instructions?
sure...

since the solenoid is just a fancy, high current, remotely controlled switch, we can use the same switch test procedure to make sure the "switch" is closing properly. depressing the Go pedal should close the solenoid and display pack voltage on the meter.

*note - for safety, disconnect and secure (tape up) the POS+ lead to controller prior to test.
-sj
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Unread 12-10-2011, 08:23 AM   #39
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Default Re: Wire smoking.. Need HELP!!!

Where does the negative end of the multimetter go?
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Unread 12-10-2011, 08:24 AM   #40
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Default Re: Wire smoking.. Need HELP!!!

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Originally Posted by carnejm View Post
New development.... I just took the resistor off and tested it will my multimeter. It read .240. I am no professional here, but I believe that means it is still good, correct?
your resistor is good ....it's withing 10% of range ...except I think your SCALE setting on the meter might be set wrong.

BY THE WAY: when i replaced the controller for the guy who had your symptoms i check the entire system. I found out his tow/run switch was defective and remained in the closed position (RUN MODE ). So we deduced that was the origional cause of smoking the controller while he was playing with the electronics .

follow "SONICJ's guide and check out the tow /run before you install a new controller. Use a meter in the OHM's position or in the "Rx1"
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