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Old 12-11-2017, 10:03 PM   #1
mgray70
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Default PDS cart not running, got a couple of charred pins

Working on a PDS cart. J1 Pin 5 is charred and the red wire in J3 tow run is also charred. The tow run switch appears to be bad (I have no continuity through the switch on run). My main question is what could have caused the heating of those wires? Controller? Gonna try to get a new tow run switch and see if the controller will power up. Any thoughts on what is this could be?

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Old 12-11-2017, 10:10 PM   #2
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Default Re: PDS cart not running, got a couple of charred pins

Here are some pics.

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Old 12-12-2017, 12:01 PM   #3
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Default Re: PDS cart not running, got a couple of charred pins

The power that feeds the solenoid coil, F/R switch, keyswitch and pedal switch enters the controller of J1 Pin-5, exits on J3 Pin-1, passes through one set of the two sets of contacts in the Run/Tow switch and re-enters the controller on J3 Pin-3. From there it goes to various pins in J1 and J4 to the various external switches and the solenoid coil.

There are three pins passing total power to the switches and coil, but only two of the tree are burnt. Might have been that those two weren't making good contact or might have been excessive current being drawn by the external switches and solenoid coil, or maybe a short in the wiring harness.

The electronics in the controller are powered via J1 Pin-4 and the other set of contacts in the Run/Tow switch, so the controller is probably okay, but fixing the burnt pins on the controller is likely to be a challenge.
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Old 12-12-2017, 01:22 PM   #4
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Default Re: PDS cart not running, got a couple of charred pins

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Originally Posted by JohnnieB View Post
The power that feeds the solenoid coil, F/R switch, keyswitch and pedal switch enters the controller of J1 Pin-5, exits on J3 Pin-1, passes through one set of the two sets of contacts in the Run/Tow switch and re-enters the controller on J3 Pin-3. From there it goes to various pins in J1 and J4 to the various external switches and the solenoid coil.

There are three pins passing total power to the switches and coil, but only two of the tree are burnt. Might have been that those two weren't making good contact or might have been excessive current being drawn by the external switches and solenoid coil, or maybe a short in the wiring harness.

The electronics in the controller are powered via J1 Pin-4 and the other set of contacts in the Run/Tow switch, so the controller is probably okay, but fixing the burnt pins on the controller is likely to be a challenge.
Thanks for the reply Johnny. I have another tow run switch on the easy because it appears to have failed. No continuity at all on either side of it. I was wondering if a short circuit fried the switch, but it doesn't look like it would have gotten both sides of the switch when only one side got hot. Maybe after that I can get power to the controller to actually test it.

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Old 12-17-2017, 05:16 PM   #5
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Default Re: PDS cart not running, got a couple of charred pins

Replaced the tow/run switch today. The cart runs, but very slow. Cart will not pass the speed sensor test, but when in diagnostic mode I get welded solenoid. Solenoid is checking out good. Could a failed speed sensor trigger a welded solenoid code?

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Old 12-18-2017, 09:44 AM   #6
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Default Re: PDS cart not running, got a couple of charred pins

A bad speed sensor isn't likely to trigger a welded solenoid error, but a bad connection on J1 Pin-5 might. In fact, "Checking auxiliary power" is the first suggestion on the error code label (attached)

The controller activates and deactivates the solenoid, so it knows when the solenoid contacts are supposed to be closed and open. The controller also monitors the voltage at J1 Pin-5 and compares it to the voltage on the controller's B+ terminal.

When the solenoid contacts are open, the voltage at the B+ terminal ought to be less than the voltage at J1 Pin5 and when the contacts close, the voltage at B+ ought to climb to the voltage at J1 Pin5. When the contacts are reopened, the voltage at B+ ought to fall below the voltage at J1 Pin5.

If the expected voltages are not seen at the proper times, a welded solenoid error will occur.

Temporarily disconnect one end of the pre-charge resistor on the solenoid's large terminals and it ought to run normally if the speed sensor is okay.
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Old 12-18-2017, 10:44 AM   #7
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Default Re: PDS cart not running, got a couple of charred pins

having jonnieB on here is like having christmas every day!...
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Old 12-18-2017, 10:47 AM   #8
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Default Re: PDS cart not running, got a couple of charred pins

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Originally Posted by JohnnieB View Post
A bad speed sensor isn't likely to trigger a welded solenoid error, but a bad connection on J1 Pin-5 might. In fact, "Checking auxiliary power" is the first suggestion on the error code label (attached)

The controller activates and deactivates the solenoid, so it knows when the solenoid contacts are supposed to be closed and open. The controller also monitors the voltage at J1 Pin-5 and compares it to the voltage on the controller's B+ terminal.

When the solenoid contacts are open, the voltage at the B+ terminal ought to be less than the voltage at J1 Pin5 and when the contacts close, the voltage at B+ ought to climb to the voltage at J1 Pin5. When the contacts are reopened, the voltage at B+ ought to fall below the voltage at J1 Pin5.

If the expected voltages are not seen at the proper times, a welded solenoid error will occur.

Temporarily disconnect one end of the pre-charge resistor on the solenoid's large terminals and it ought to run normally if the speed sensor is okay.
Thanks Johnny, I didn't know exactly what the purpose of J1 pin 5 was, but that makes perfect sense. I'll try that this afternoon.

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Old 12-18-2017, 10:49 AM   #9
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Default Re: PDS cart not running, got a couple of charred pins

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having jonnieB on here is like having christmas every day!...
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Old 12-18-2017, 10:52 AM   #10
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Default Re: PDS cart not running, got a couple of charred pins

Johnny, where do you check the auxiliary power? Is that J1 pin 5?



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