Just finished installing everything and now…. nothing?

Superman51

Just finished installing everything and now…. nothing?
Hello everyone,
Today is just one of those days . I finished installing all my goodies, jumped in the seat, turned the key switch on, and…………nothing. I attached some pictures to see if the experts can tell me if I installed something wrong. I followed all the instructions and took plenty of pictures before so I knew how to reinstall everything. I upgraded everything and switched to a 48V system. The pack has plenty of power and the reverse sound comes on when I put it in reverse. Other than that, I get nothing. I have checked ALL the connections, even the key switch. I can turn the key on, press the throttle, and there Is no response anywhere. Here is a list of all the upgrades:
D&D series motor
700A Logisystems controller
HD F&R switch
HD 400A 48V solenoid
2 gauge cables
Added 2 more 6V batteries

The only thing I can think of is that I ordered the 700A ITS controller. I was told that is the one I needed but I’m not sure. Also, the HD F&R switch did not come with instructions. I reinstalled it the way my old one was setup. The new one maybe different? Thanks in advance of any ideas.

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BGW

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Superman51

Ok, I’ve been tinkering with it some more. I tried several different things and still nothing. I did notice some heat coming from the solenoid and the resister was HOT! I disconnected everything and now letting it cool. Is the resister directional? I know that the diode is but I just stuck the resister on. Maybe this can help diagnose it.

OU4LIFE

just wanted to say good luck and bump it back to the top so you can get some help.

Superman51

Thanks man. I started out the day with the hopes of cruising around in my cart that has been out of service for the past 3 weeks. Evidently, the HD solenoid’s posts are bigger than the 2 gauge cable connectors. I was going to bore out the holes with a drill bit that was already on my high torque drill. I was in a hurry and got stupid. I was holding the cable with one hand and started drilling with the other. The drill bit caught the cable and wrapped it and my hand around it. The large teeth of the tightening gears ate my hand up! HUGE lesson learned! I put some lidocaine on it and cleaned it up so I could finish the cart. Now I’m just gimped up and still no cart

Attached Images

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Superman51

Ok, this came to mind also. The small red wire going from the controller to the solenoid was not long enough. I spliced another wire in the middle to extend it but that wire was a little larger. Also, a friend was helping me hook all the batteries up and said that “it might have sparked” when he was putting the cables on. My guess is that is translated into “I wasn’t paying attention and it definitely sparked”.

mauistardog

I put the exact same upgrade not to long ago on my cart. I also had a problem. Just relax it will come together. You can search my old thread called. "48v conversion gone bad" I got pics of my solenoid if you want to compare pics on the set up. One of the smart guys will come along and tell ya which wire is in the wrong place. Clean the hand up and drink a beer and it will make more since in the morning. Did you take pictures of you old set up of the wires ? That helped me put it back together.
good luck
joe

athomas03

My small wires to my controller go: Red, Black, White, Orange Looks like you may have them out of order, but I have an Alltrax and you have a Logi. That's one thing, also play with you F/R. I did my conversion and the cart wouldn't go but, it was because when my handle was in forward it wasn't actually lined up in the switch itself. Once I adjusted some it made contact and all was good. That's a couple of things to check, hope you get going soon, no more blood shed!

scottyb

the small black and white throttle position signal wires can be swapped around = no problem but if you are not getting a solenoid click then my guess would be your not getting power to the small red wire at the controller. Or solenoid activation. Where does the mall red and white wire from the charger receptacle connect up ?

Superman51

Thanks Mauistardog, there was plenty of beer after that. I’m about to check out your thread. I took plenty of pics before because I was going to do a full write up on BGW and to assist me in the reassemble.

Athomas03, I followed Logisystems diagram for wiring the small wires. It was not the same order that my other controller had but………it’s their controller. As for the F/R switch, it is actually not hooked up. I’m about to paint the exterior and have everything off right now. I just manually moved it from F to R and can hear it click.

Scottyb, I have the protech onboard charger that is hooked up on the pack near the controller. It has a black and red wire that can be seen in pic 3. The solenoid is not making any noise, but the resister did get really hot earlier when I was tinkering with it.

FYI- my friend that was helping finally admitted that the wires did spark when he was hooking it up. He said he accidently touch a positive to another positive.

Superman51

The solenoid wiring goes like this:

Right side-
=Large terminal= 2 gauge wire to positive battery pack post and blue wire from throttle
=small terminal= black wire to controller

Left side-
=Large terminal= 2 gauge wire to controller (B+)
=small terminal= red wire to controller and red wire from throttle