2002 PDS, no go after cable sparking...

gornoman

I was helping a friend re-cable his 2002 PDS cart. I warned him about sparks. We had the cart in "TOW" and a mid-pack battery cable removed. I was making the new cables, one at a time while he cleaned the terminals. He would install the new one and hand me the next old one to copy. He finished all the battery top cables and was disconnecting a cable from the stock Curtis controller when the cable slipped and fell back at the controller. He had inadvertantly installed ALL of the new battery cables, and this allowed full pack voltage to throw a 1.5" spark at the controller. I was worried when I saw it.

We finished the rest of the cables, and the cart is dead in the water. Lights work, reverse buzzer sounds, no forward or reverse. Cannot read any voltage on the small posts of the solenoid under any conditions. Solenoid does not engage at all. We tried jumping the Reed switch, no luck (I expected this). I was gonna tear up the floormat and check the ITS micro, but he ran out of time and had to leave for a wedding.

Under these circumstances, if it's not the ITS micro, I suspect a blown controller. Any other ideas? BTW, cart is 100 miles away at the campground.

BGW

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dirtysouth

There's a fusable link in the charger receptacle. Hopefully that's it.

tonyton

There is a fuse in them. they started to locate the fuse at the positive terminnal of the battery going to the controller, located away from the box and other components. Some caught fire, I was told. I don't know much about these, but I've seen that fuse.

mikesmotortoys

"Fuse" is the reed switch he mentioned. I'll have to think on this one! Are you getting any soleniod activity?

scottyb

I think the solenoid gets it's constant ground connection from the controller? I'm not positive.... I know the DCS does.

gornoman

No fuse present, Reed switch bypassed, no solenoid activity. I sure hope it's a fried ITS micro or else it's Alltrax time.....

gornoman

Because I have a good reverse buzzer and no voltage on the solenoid primary, I will order an ITS Microswitch. If that's not it, I will hold the micro in my parts box and order him an Alltrax.

Thanx guys. I will update this in a week when I know more.

gornoman

Found the problem, but I can't post the pix until later today. You're not gonna believe what the solution was........

Trust me, no one has seen this before.

mikesmotortoys

gornoman

Patience, my Texan friend, patience. I promise, you will be stunned when you see what this bonehead did.....


ps: I am not the bonehead in this case.