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Unread 07-30-2013, 04:52 PM   #1
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Default Pre-charge resistor burning up!

Hi everyone I am new to BGW and I am in need of some help. I recently replaced my batteries in my 1999 48 volt DS with 6 new Trojan 875's and to continue with the replacements and upgrades I bought a pre made 4 gauge battery cable kit. When I was done replacing the cables one at a time to ensure I got them correct, the larger of the two resistors on the solenoid started smoking and at the same time if I hit the gas my cart immediately goes full throttle even though I'm just barely touching the gas. It will spin tires on concrete and it's never done that before. I bought a new resistor from the local golf cart parts house and it gets hot as soon as I turn the key on and it still does the full throttle thing as soon as I hit the gas. Also before the cable replacement everything worked fine. The negative cable fit through the OBC but just barely. Please feel free to ask questions I will do my best to give an intelligent answer. I used to be a car mechanic so I am inclined to work on things. Help!
Thanks
Alex
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Unread 07-30-2013, 05:46 PM   #2
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Default Re: Pre-charge resistor burning up!


double check wiring

95-03 48 volt electric club car wiring diagram
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Unread 07-30-2013, 06:36 PM   #3
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Default Re: Pre-charge resistor burning up!

I will double check it thanks!
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Unread 07-30-2013, 10:43 PM   #4
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Default Re: Pre-charge resistor burning up!

Definitely sounds like funky wiring first and foremost, if not sounds like maybe the micro switch on the throttle could be sticking open causing the solenoid to be activated constantly, maybe throttle issues too? Out of curiosity, does the solenoid click when you first depress the go pedal or does it click when you put it in gear w/o throttle down?
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Unread 07-31-2013, 10:40 AM   #5
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Default Re: Pre-charge resistor burning up!

The solenoid clicks when you first press the throttle.
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Unread 07-31-2013, 10:40 AM   #6
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Default Re: Pre-charge resistor burning up!

I am heading out to look at the wiring now I will post with my findings.
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Unread 07-31-2013, 11:10 AM   #7
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Default Re: Pre-charge resistor burning up!

Quote:
Originally Posted by 125rmodel View Post
I am heading out to look at the wiring now I will post with my findings.
also check that solinold is not stuck in the open postion
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Unread 07-31-2013, 08:06 PM   #8
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Default Re: Pre-charge resistor burning up!

I went out and checked the wiring this morning and I did swap the cables one at a time except for two on the controller I had to have both off at once because of the direction the bolts were. Sur enough I mixed them up ��. I corrected the cables and now it works like a charm. But information wise 4 gauge cable fits through the OBC but it is a tight fit. Thanks crash test dummie I appreciate the help. I do feel dumb though!
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Unread 07-31-2013, 09:02 PM   #9
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Default Re: Pre-charge resistor burning up!

hey we have all done it .. glad you found it
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Unread 07-31-2013, 11:20 PM   #10
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Default Re: Pre-charge resistor burning up!

Agree with CTD, an easy mistake to make that we've all done. I can't count the times I've worked on a cart and left the pack unhooked at the main positive and negative terminals only to wonder why it still won't go. Glad its resolved, have some fun on it!
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