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Old 12-13-2010, 03:04 PM   #1
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Join Date: Nov 2010
Location: Ixonia,WI
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Default Resistor coil is broke! Can I repair, etc.?

I have a Hyundai 36 volt, Model HGB-1, Serial Number B1000960. I do not know the year. I had it running and the resistor coil heated up and broke in two. I am having a very difficult time finding a replacement. It looks like it has 17 coils and wires from the Speed Controller attaching at points along the coil.

My questions are:
are there replacements? ( I searched all the "normal" cart sites and
found nothing.)
can I weld the broken pieces together?
I see Yamaha G1 to G9 uses a 21 coil unit that looks somewhat similar
to mine. Will it work?

I believe the resistor's function is to control voltage to the motor. But why would it heat up so much to cause it to break?

Lastly, I don't want to convert this cart to an electronic resistor that pulses the voltage to the motor. Reason being they are quite expensive.

Thanx, in advance, for any thoughts.
yo-dt
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Old 12-13-2010, 03:19 PM   #2
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Default Re: Resistor coil is broke! Can I repair, etc.?

Some utility coils are available if you know the gauge of the wire and the length in the coil.
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Old 12-13-2010, 03:50 PM   #3
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Default Re: Resistor coil is broke! Can I repair, etc.?

I can determine the length and gauge. Where do I order it from?
Thanx
yo-dt
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Old 12-13-2010, 04:54 PM   #4
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Default Re: Resistor coil is broke! Can I repair, etc.?

Call one of the sponsors who advertises the lowest prices
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Old 12-13-2010, 05:20 PM   #5
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Default Re: Resistor coil is broke! Can I repair, etc.?

I have seen large resistance heating coils repaired
with crimp collars and ((I believe silver solder)).
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Old 12-13-2010, 06:45 PM   #6
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Default Re: Resistor coil is broke! Can I repair, etc.?

I think the melting point of silver is too low... By the time you melt them you have pretty much destroyed the metal so even if you weld them up I dunno if it would work or if so for how long, you know? ... they only list for like $20... when you find them.
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Old 12-13-2010, 08:06 PM   #7
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Default Re: Resistor coil is broke! Can I repair, etc.?

OK Scottb, here is the challenge. Tell me what the resistor is made of and at least one retailer you know that sells these coils. I can find no help with BGW vendors.
yo-dt
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Old 12-13-2010, 08:40 PM   #8
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Default Re: Resistor coil is broke! Can I repair, etc.?

Steel. Nivel ... Come on you gotta have a tougher question than that
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Old 12-17-2010, 06:28 PM   #9
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Default Re: Resistor coil is broke! Can I repair, etc.?

i belive they are actually nickel cromium or some mix of other stuff
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Old 12-17-2010, 07:19 PM   #10
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Default Re: Resistor coil is broke! Can I repair, etc.?

I don't know what that is but this stuff rusts like steel?
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