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Unread 05-31-2013, 03:39 PM   #1
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Default Voltage drop accross solenoid, resistor hot

I have a 2007 ezgo PDS electric golf cart. The voltage on battery side of solenoid (large post) is full 37 volts. Other side shows only 0.5 v and resistor joining the two is hot. This is the case when cart is on or off and in neutral. The cart will not move at all. Could this be a bad resistor?
Thank you for any help you can give me
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Unread 05-31-2013, 06:18 PM   #2
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Default Re: Voltage drop accross solenoid, resistor hot

Welcome to BGW!

For starters, 37.0V is less than 70% charged and the battery's plates are sulphating as we speak. They need to be charged. (38.2V is fully charged for a 36V battery pack.)

However, that is high enough to troubleshoot cart.

Before solenoid clicks, you should have full battery pack voltage on solenoids battery side large terminal and a few volts less the pack voltage on the solenoids controller side large terminal.

After the solenoid clicks, both large terminals should have the same voltage.

Sounds like your solenoid isn't clicking (activating) or if it is, the contacts are bad.

What is happening, it the controller is turning on and trying to suck upwards of 300A through a 250 Ohm 10Watt resistor.
The resistor may be bad after getting hot, but it wasn't the problem, it is collateral damage.

-----------
Can you hear the solenoid click when pedal is pushed?
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Unread 05-31-2013, 06:48 PM   #3
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Default Re: Voltage drop accross solenoid, resistor hot

I think the back half of the bank are a bit weak. You can tell that there are two different sets of batteries. I still get the 6.2 volts on each but a load test shows them to be a little weak.
The solenoid does not click at any time. The battery side of the solenoid matches the battery bank. The controller side only shows 0.5 volts.
I removed the resistor and got a zero reading on the controller side
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Unread 05-31-2013, 07:05 PM   #4
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Default Re: Voltage drop accross solenoid, resistor hot

Thank you for the welcome. Putting the cart on charge to see if I can bring it up
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Unread 05-31-2013, 09:48 PM   #5
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Default Re: Voltage drop accross solenoid, resistor hot

I thinks when voltas are up and good if ya have the same issue controller
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Unread 06-01-2013, 01:38 AM   #6
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Default Re: Voltage drop accross solenoid, resistor hot

Quote:
Originally Posted by RugDr View Post
I think the back half of the bank are a bit weak. You can tell that there are two different sets of batteries. I still get the 6.2 volts on each but a load test shows them to be a little weak.
The solenoid does not click at any time. The battery side of the solenoid matches the battery bank. The controller side only shows 0.5 volts.
I removed the resistor and got a zero reading on the controller side
If the solenoid never clicks, you have one of three problems: (Listed alphabetically)
1. Bad controller
2. Bad solenoid
3. Bad voltage at one or more of the following 13 Test Points.

!!!!!! Be sure to place Run/Tow switch to Tow before Disconnecting or reconnecting anything electrical !!!!!!

Disconnect J1, spray the contacts in both Plug & Jack with contact cleaner and repeatedly insert Plug back into Jack while contacts are still damp.

Repeat for J3 and J4.

If that doesn't do the trick, jack rear wheels off ground and put rear of half ton cart on jack-stands so it doesn't run over somebody or something while troubleshooting.

Using a DVM (Digital Volt Meter), measure and record battery pack voltage to the nearest 1/10 volt. (IE: Fully charged 36V battery pack will be 38.2V or slightly above.)

Leave DVM negative test lead attached to battery pack's main negative terminal.

With Run/Tow = Run, Keyswitch = ON, F/R = F , Pedal depressed until solenoid clicks; Measure voltage at: (While Plugs are inserted into Jacks)
J1 Pins 1, 3, 4, 5, 6, 8 & 9
J3 Pins 1, 2, 3 & 4
J4 Pins 1 & 2

Every one of the 13 test points listed should have FULL battery pack voltage.

If any are less than full battery pack voltage, fix the switch and/or wires attached to that switch. (Pin numbers and switches shown on attached schematic)
Attached Images
File Type: jpg Wiring Diagram - PDS - Solenoid activation traced.jpg (69.7 KB, 0 views)
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Unread 06-01-2013, 09:01 AM   #7
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Default Re: Voltage drop accross solenoid, resistor hot

To test those voltages, you say the pedal is depressed until the solenoid clicks. The solenoid does not click at all. I don't think I can check those things
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Unread 06-01-2013, 09:14 AM   #8
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Default Re: Voltage drop accross solenoid, resistor hot

Get the pack fully charged and then concentrate on getting the solenoid to click. That is step 1 and 2
Follow the solenoid activation circuit below to find where your problem is.
The solenoid will read 36-38v across the 2 small terminals when it is energized (clicks)

I hope this helps
Attached Images
File Type: jpg Ezgo PDS solenoid activation diagram.jpg (142.4 KB, 0 views)
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Unread 06-01-2013, 09:41 AM   #9
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Default Re: Voltage drop accross solenoid, resistor hot

Quote:
Originally Posted by RugDr View Post
1. To test those voltages, you say the pedal is depressed until the solenoid clicks.

2. The solenoid does not click at all.

3. I don't think I can check those things
1. Should have said, press pedal until pedal microswitch closes.

2. The solenoid not clicking is the reason for checking the voltage at the points listed.

3. Hire someone that can.

-----------
The PDS drive is more or less a Fly-by-Wire system. The controller does everything and the external controls tell the controller what the operator wants the cart to do.

The way the operator gets controller to activate the solenoid is applying B+ (battery pack voltage) on seven input pins on the controller, which is done by five different switches.

That doesn't add up to the 13 test points I listed because some switches apply voltage to more than one pin and some of the pins listed are the voltage source for the external controls.
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Unread 07-08-2015, 09:31 PM   #10
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Default Re: Voltage drop accross solenoid, resistor hot

I know that this is on old thread, but I'm having a similar problem. The cart (pds) will run for a few mins and then quit. When it quits I'm not getting voltage across the two small terminals on the solenoid. If I put it in tow and hold the pedal down for a few mins, then go back to run, it will go again for a few mins.
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