Solenoid installation gone bad

[tielei]

I just put a new solenoid, diode, and resistor to a 95 Medalist series model. Ordered the parts from buggiesunlimited and feel confident I purchased the correct components.

The cart was running fine before except for upgrades it was losing way more speed than it should have, so I was trying to address that issue by replacing these three components.

I did disconnect the positive power to the 36v system before any work was done each time I worked on the components. My first attempt to test the cart was a sluggish start, the cart moved forward about 10 feet and stopped. I did smell something like electrical so I found the new diode was broken and smoke marks on the bottom of the solenoid where the resistor wire was.

From this point I tried every combination of new and old components possible, each time disconnecting batteries and switching the components then checking the results by trying to move the cart in both forward and reverse with the only response was the signal from being in the reverse gear.

I did not hear the solenoid click after any of the component changes that I can
remember. It is not clicking now after I put the original components back.

Thanks for your help

[Volt_Ampere]

You probably had the diode installed backwards. That smokes it every time.

[cgtech]

due to the backward diode, it probably now needs a gas pedal microswitch, or a charge port reed switch , or both.

[tielei]

Backward diode, got it. That will possibly blow other components, got it. How about the solenoid and resistor that are new. How do you check the solenoid and resistor? I assume now I could have put the resistor on backwards, too.

[cgtech]

resistor is not polarity sensitive, just needs to be on the large terminals of solenoid, its probably still good. solenoid is fine, it never got to turn on, diode shorted and killed (reed switch or pedal switch) before solenoid ever got on.

[tielei]

Awesome, ordering both now and another diode. Thanks so much. I will have to ask the proper way to install the diode when it comes in.

[scottyb]

If you order from BGW site sponsors instead of the old BGW enemy...... you would have gotten instruction showing you how to avoid all this trouble and added expense.
See diode and resistor install instruction below.

[tielei]

Thanks, Scottyb. I will order from bgw instead of unlimited this time. Haven't processed my cart yet, so I am going to delete it.

[scottyb]

Excellent, just pick any BGW sponsor from the many listed.
You have the instruction you need now above.

[Volt_Ampere]

Diode goes with the banded end towards positive on the solenoid. You need to check the wiring diagram to figure out which terminal is positive. When the solenoid is not activated, both sides are at the same positive potential.