Diode on solenoid melts

[Mooncarter]

Originally Posted by Chandler1991

Mooncarter it’s a fnr with handle I’ll take a picture of it tomorrow

OK. But I don't need to see a pic of the FNR. The reason I asked is because there are a lot of carts of this vintage that began life with 2 solenoids.

I now know which wiring diagram to look at because yours did not come with 2 solenoids. I asked you this in post #5.

[Sergio]

Maybe the colors look different in the picture, but it looks like You have a 240Ω pre-charge resistor, that is way too small for 48v and it will get hotter than the 5 watts rating could dissipate.

The correct size for a 48v system is 470Ω x 10 watts.

Also, why is there two wires on the negative activation circuit?

Is the OBC lockout by-passed and the old wire left in place?

[Mooncarter]

Good catch Sergio. I knew something did not look right about that resistor.

[Mooncarter]

Chandler this is what you should have:

On one large post: Red cable to pack positive, Red to OBC, Green to key switch and red to reverse buzzer.

Other large post: Yellow cable to controller.

One small post: Yellow to OBC. (This is your neg. side)

Other small post: White/Black to FNR micro, Red to controller pin #1.

[Mooncarter]

And as Sergio pointed out, there should be only 1 wire on the neg. activation (small) post.

Follow them and see if one goes to B- on the controller or to pack negative.

[Chandler1991]

Thanks guys was a 14hr day at work today I tried looking at wires and there’s all kind of stuff cut out I will be pulling body off to get a good look at where everything goes.

[Mooncarter]

Just remember your solenoid has a built in diode that has to have the small wires oriented one way only. Most others it does not matter.

[Chandler1991]

Ok so body is off. One yellow wire goes to obc red wire withe resistor or diode built in goes to obc. Other yellow wire goes to a relay under dash. Big yellow to controller big black to positive. Other red goes to a white wire black trace to the micro switch on for switch. Also I found a box under floor that has wires going to it not sure what it is.

[Chandler1991]

Also when I bought new controller it was a upgraded 700 watt

[Sergio]

Your last picture shows the Serial Number, You have a DS Villager that was refurbished in 2003.

Here is Your wiring diagram which includes that additional yellow wire from the Solenoid to the brake lights relay: