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Unread 12-09-2011, 12:30 PM   #1
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Default Wire smoking.. Need HELP!!!

I smelled some some coming out from near my controller. Upon investigation I found it coming from this jumper wire between the main power supply and the controller. Need help identifying what it is and how to fix. See attached pictures.

In the first picture you will see the two yellow wires, the smoking jumper came from between those two. The second picture is the jumper that was smoking.

It seems that this is a fuse of some sort. It is stoppong the power from getting to the controller and eventually the motor.

Just to explain a little more of what probably caused this. I was trying to take the speed sensor off the cart (not much room) and I had my arm reseted on the motor terminals. I forgot to kill the power first! Needless to say when my watch touched it it started sparking pretty bad. I immeadiatly killed the power to the cart, and then removed the sensor.

I got my new speed sensor in today, put it on, reconnected the power and this diode/resistor/fuse started smoking and the cart would not move. I checked to see if there was power at the motor or controller and there wasnt.

I can only assume that it had something to do with the sparks when I touched the motor.

Any help would be greatly appreciated!!!
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File Type: jpg IMG-20111209-00039.jpg (82.3 KB, 37 views)
File Type: jpg IMG-20111209-00040.jpg (49.8 KB, 33 views)
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Unread 12-09-2011, 12:49 PM   #2
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Default Re: Wire smoking.. Need HELP!!!

Quote:
Originally Posted by carnejm View Post
Just to add to this... It seems that this is a fuse of some sort. It is stoppong the power from getting to the controller and eventually the motor.
That is a diode. Maybe from the solenoid. An expert will have to chime in.
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Unread 12-09-2011, 01:24 PM   #3
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Default Re: Wire smoking.. Need HELP!!!

That is a resistor. I believe a 240 ohm. I'm not sure of the value. One of the electronic techs will help on this I'm sure!
Also why it is overloading I can't say either, I'm not that familiar with CC, so hang in there, help is on the way!
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Unread 12-09-2011, 02:09 PM   #4
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Default Re: Wire smoking.. Need HELP!!!

Man, you are lucky! Betcha you won't do that again! I think any of us that have started working on electric carts have learned a bunch from this site! I know I sure have!
Back to you, I honestly don't know what could have happened when you had your " mishap ". Which two terminals were involved when your watch shorted them? This may help on figuring this out.
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Unread 12-09-2011, 02:12 PM   #5
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Default Re: Wire smoking.. Need HELP!!!

If you are looking into the access door at the two terminals going into the top of the motor, it was the one on the right. (I have a 2006 Club Car Precedent 48v)
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Unread 12-09-2011, 02:13 PM   #6
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Default Re: Wire smoking.. Need HELP!!!

And yes.... I feel pretty lucky! I wont make that mistake again!
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Unread 12-09-2011, 03:21 PM   #7
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Default Re: Wire smoking.. Need HELP!!!

Any electronic techs out there that can help me out? I am just sick to my stomach.... I hope I didn't burn up the controller or something!
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Unread 12-09-2011, 03:37 PM   #8
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Default Re: Wire smoking.. Need HELP!!!

After some research, I believe the suspect part is PN: 102522701 (Asm, Pre-charge Resistor)

Beyond that, I am not sure what it does or anything.

See picture attached
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Unread 12-09-2011, 03:41 PM   #9
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Default Re: Wire smoking.. Need HELP!!!

Quote:
Originally Posted by carnejm View Post
Any electronic techs out there that can help me out? I am just sick to my stomach.... I hope I didn't burn up the controller or something!
That appears to be the "pre-charge resistor" . . . see page 12E here:

http://bennettgolfcars.ca/manuals/cl..._precedent.pdf

Should be inexpensive to replace (under $5), even at local CC dealer . . .
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Unread 12-09-2011, 03:53 PM   #10
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Default Re: Wire smoking.. Need HELP!!!

Would the Pre-charge Resistor being burnt up keep my cart from moving? Because there is no power getting to the motor.
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