48v Conversion and Upgrade ?s

[jeffro22]

have a 2004 ezgo series cart.. Just upgraded to a 48v system, with all new cables, F&R switch, 500 alltrax controller and solenoid.

Running into a wiring issue i think. cart works fine, except the controller flashes LED codes when the key is turned off. It is showing a pre-charge failure code when the key is off, When the key is on it goes away and everything seems to function fine.

I do have a "jumper wire" from my large terminal of the battery side solenoid going back to the small terminal of the solenoid "controller side", which seems out of place (but was wired this way before upgrade)

When I remove that jumper wire i loose all power regardless of key position,

any help is appreciated. I am concerned that if i leave it the way it is now I will burn out the solenoid or controller since it seems to always be powered

[yurtle]

Do you have a resistor on your solenoid? If so, remove one side and test it. If not, that may be the problem.

I have a 500 amp AXE, but yours may be newer.

[sportcoupe]

The small jumper wire you describe needs to be there. Do you not have a pre-charger resister across the large solenoid studs?

[Revolution]

Is your precharge resistor warm or hot with the key off? Axe controllers don't normaly flash any codes when your not applying key switch voltage.

I would guess your controller is staying powered on with the key off.

Check for voltage on pin 1 from b- with the key off.

[jeffro22]

I do have the correct pre charge resistor in place. This was complete kit from scottieb... so it is most likely something on the cart side wiring. I am guessing the guy i bought it from messed with the wiring at some point. not sure why. I might try to sketch out my current wiring and see if anyone notices anything out of place

[JohnnieB]

Pictures would help.

Sounds like the previous owner re-arranged the control wiring a bit.

In a series cart, there aren't any small wires on the solenoid's large terminals, just the heavy cables and the pre-charge resistor.

When conventionally wired, the solenoid coil doesn't have positive pack voltage on the coil (small terminals), nor is the controller powered-up, until a direction is selected, key is ON and the pedal is pushed.

[yurtle]

Which controller do you have? As mentioned, AXEs don't know whether a precharge resistor is installed or not.

That's why I like old school AXE series controllers. We need to know what you have, so you can get the correct wiring diagram.