Troubleshooting hot resistor and burnt black wire

Yammer

05 EZGO 36v to 48v conversion: new Alltrax AXE4855, HD solenoid, HD fnr, 4 awg cables, Trojan 875 8v batteries

I had a problem with the resistor on the large posts of the solenoid staying extremely hot constantly with or without the key on. No power apparently to the controller because LED did not light at all.

I read older posts instructing to jack up the rear of the cart, take the resistor off the solenoid and jump the large posts with a 4 awg cable to check if the solenoid was stuck or bad.

Once I set it up this way, the second the positive lines hit the battery post it **** near melted that battery post down, huge spark, and blew the black wire off running from the small terminal post on the solenoid to the B- of the controller.

Now, as a result, once I hooked up the resistor to the solenoid again and connected the positive lines to the battery post, it stayed cool (key off) and the LED on the controller is now solid green. Black wire not hooked back yet. ??? Any insight on this matter? Do you think I blew something? I'm scared to move forward now.

Thanks,
Yammer

BGW

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scottyb

What solenoid are you working with and what is the power route to the solenoid & controller activation? Is this a series cart? Some pics of your controller connection and solenoid wiring will help ....

Yammer

Scottyb, thanks for your help!

I'm sorry but I don't know how to insert the pictures, it asks for my URL when I try to insert an image and I don't have them online. I'm not very computer savy.

This is a series cart.

The large posts on the solenoid are connected (on the short post 1 side) to the battery positive through a CNN 400 fuse, and (on the short post 2 side) to the B+ of the controller. Then on the short posts, I have the red wire connected from 1 to the throttle switch red and #1 post on the controller next to the LED light, and the black wire from the 2 to the B- on the controller (this is the black that blew off when I jumped the solenoid without the resistor).
The 470 ohm resistor is connected between the two large posts on the solenoid, and a diode is connected with stripe towards the small 1 (red side) terminal of the solenoid to the small 2 terminal (black side)

I'm using a Heavy Duty Solenoid, 48V, 400 Amp Continuous Current, 800 Amp Inrush Current with a 470 OHM Solenoid Resistor, Used With Large 400 amp Solenoid 3/8 Ring

Alltrax 4855 AXE 500 AMP (2 MIN), 700A Peak (10 Sec.) Programmable Electronic Speed Controller, for Series Motors, 24-48V, - EZGO ITS Throttle

EZGO GE "The Raptor" 6.1 Non-Peak HP @ 4600 Rpm 36v-48v Electric Motor

Thanks again,
Yammer

scottyb

Remove the red wire going from the solenoid small post to the controller small post next to the led. that is the power that turns the controller on... use another source such as the key switch or the F&R micro switch (not the pedal switch). It should already be on before the solenoid activates....

Yammer

Ok, so if I run it from the microswitch on the fnr, which place do I connect it to?

And what do I do with the red wire from the pedal switch then, does it just sit there not connected to anything?

One more question: if I connect it to the key switch, there are four connectors on the back, B-B1-I-L, which do I connect to? The green wire is connected to the L and the blue to the I, both run into the area of the fnr. Is that correct as well?

Thanks!

scottyb

Can you post a pic or link us to the diagram you are using to hook your controller up?

scottyb

This is from the alltrax site the top pic is how your cart should be hooked up wait......1 minute.

scottyb

Is this your cart? there are more than 2 ways to skin this cat but you can't go wrong following the alltrax diagrams.... or click on the image below once and then when it opens once again to full page view. Print it out and compare to your cart.

http://www.alltraxinc.com/files/Doc1...k-wire-dia.pdf

Attached Images

AXE series Ezgo.jpg (114.7 KB, 26 views)

Yammer

I don't have a reverse switch that I know of that your diagram shows, and the Alltrax wiring diagram that I am using is not on their website. The company that I bought everything from sent me a wiring diagram that is for EZGO 1994 to 2000, but I have a 2005 TXT. But the wiring colors and all that are on the diagram that I've been using match up. It's a diagram from Alltrax just like the one you sent to me.

Should I use the one you just sent to me?

Also, if I knew how to link everything to you I would. I have pictures and this pdf diagram from Alltrax but don't know how to get it to you. I'm sorry.

Yammer

This is the wiring diagram that I was given to wire my cart. Is this the correct way?

https://secure.golfcarcatalog.com/do...O-Wire-Dia.pdf

https://secure.golfcarcatalog.com/do...O-Wire-Dia.pdf