EZGO Trouble

droptine27

I have a 2002 ezgo pds that i put an alltrax 500 amp controller and a new 48 volt solenoid re wired everything with new 4ga. cables ive been riding it for 2 months or so and this weekend i was taking my daughter to the deerstand and out of nowhere i heard something sizzling and i looked under seat and i noticed about 1ft of my wiring harness was burnt. I replaced the wires that were burnt and i still have no power to anything when i press the gas pedal i dont get a click from the solenoid. but i will say that my resistor gets super hot when its connected to both sides of solenoid, is this normal? what else can i look for?

BGW

__________________
This advertising will not be shown in this way to registered members.
Register your free account today and become a member on Buggies Gone Wild Golf Cart Forum

scottyb

When I see the resistor get smoking hot it is because the solenoid is not closing and the control is trying to draw pack voltage through the resistor.
Try a solenoid by pas and see if the cart runs.


Which wires melted?

droptine27

How do I do a bypass? Also could my Reed switch be bad? The 8wires running down frame rail.on.passenger side is what burnt they only burnt about a foot.long

scottyb

Put the cart on jacks so the rear wheels are off the floor. Key off, Run/Tow switch off if you have one.
Remove the main Negative cable. remove either one of the heavy solenoid cables and place on the opposite side so that both heavy solenoid cables are on the same terminal.
Snug, do not over tighten the terminal.

The solenoid safety switch is now eliminated from the system. Reconnect the main neg., flip the run tow switch if you had one and test the cart, if the wheels move you have a solenoid or solenoid activation problem.
If they don't move you have a controller/motor or F&R problem.

droptine27

OK could the Reed switch be a problem

scottyb

It could be

scottyb

Based on your call, you will need to get a 3 amp Diode for that 400a 48v solenoid.
It does sound like the solenoid activation wire got shorted out when it was crushed by the bouncing battery.
2 things;
1 = tie down the batteries. The cases are plastic and they won't take much bouncing around.
2 = You should check your frame for voltage. The frame should be neutral. Somebody may have grounded the lights or such, never ground to the frame on a golf cart.

Here is the solenoid activation circuit. Repair the circuit and see if the solenoid works.

Attached Images

Ezgo PDS solenoid activation diagram.jpg (142.4 KB, 0 views)