Confirmation of Controller Failure

[Chalfin]

I also ran the code tonight...3-1 (solenoid Driver failure).....replace controller
Can you trust that??

[JohnnieB]

Originally Posted by Chalfin

Ok....just did the continuity test and its jumping all over the place....

If you hear it clicking, this probably means a bad solenoid.

Originally Posted by Chalfin

J1-pin 4=37.1
J1 pin 5=37.1
J3 all pins=37.0
J4 pin 1=0.00 before solenoid click and 36.6 when solenoid clicks
J4 pin 2=37.0 before solenoid click and 36.6 after solenoid click
J4 pin 4=14.5
J4 pin 3=.9

Looks good.
J4 Pin-3 is a bit high, but it would run and adjusting the plunger in the pedal box might bring it into range.

Originally Posted by Chalfin

I also ran the code tonight...3-1 (solenoid Driver failure).....replace controller
Can you trust that??

I trust the computer inside the controller is sensing electrical conditions that trigger that error code, but that is as far as my trust goes.

Please note that replacing the controller is the second corrective action suggested. The first is checking the solenoid coil wiring.

Measure the voltage across the solenoid coil (small terminals).
Should be FULL battery pack voltage when solenoid clicks, or close to it.

--------------
My guess is that a good solenoid would put the cart back on the road, but I cannot completely rule out the controller yet.

Personally, I'd bypass the solenoid contacts to see if the cart would run.

[Chalfin]

What is the safest way to bypass te solenoid?

[scottyb]

Since it is a PDS cart put the run/tow switch in tow before proceeding with any electrical work at any time.

The simplest way to by pass the solenoid function is to move the controller side cable to the battery side terminal - so that both big cables are on the same big terminal.

Put the run/tow switch back in the run position and with the cart on jack stands see if the wheels move. If they move in one direction, test the other direction. Do not rev the motor or run for extended time. Motor or personal damage can result. It is sufficient to see the wheels turn in both directions at a rate that varies with the gas pedal. Be conservative.

[JohnnieB]

Flip Run/Tow to Tow
Disconnect the B- cable from the main negative terminal on battery pack.

The solenoid's controller side large terminal connects to motor A2 and Controller B+ terminal, so it will have either 1 or 2 cables on it. Connect the cable from the battery side large terminal to the cable, or cables on the controller side large terminal together with a bolt and position the connection so it will not touch anything.

Reconnect B- cable to battery pack, flip Run/Tow to Run.

The cart will run slowly because the controller will detect welded solenoid contacts (Error code 3-2), but it will run.

You will have the potential of a runaway cart, so be careful.
Turning key off or shifting F/R to neutral, will shut off controller.

[scottyb]

Curious to know if in fact the cart can know this the first time out (from run/tow switching to go). I suspect not.


PS
The safest way to bypass a solenoid is to make 2 simple test on the solenoid with the meter and avoid the bypass altogether...

[JohnnieB]

Originally Posted by scottyb

Curious to know if in fact the cart can know this the first time out (from run/tow switching to go). I suspect not.


PS
The safest way to bypass a solenoid is to make 2 simple test on the solenoid with the meter and avoid the bypass altogether...

I'm not sure when the welded contacts error is triggered.
It is comparing the voltage on J1 Pin-5 to the B+ terminal and could be looking for the voltage on B+ to climb to the voltage on Pin-5 when the solenoid is activated, or it could be looking for the voltage on B+ to decrease below the voltage on Pin-5 when the solenoid de-energizes.

If it was looking for the voltage to drop when the solenoid contacts opened, it would run normally the first time the contacts closed.

I most definitely agree it is safest not to bypass the solenoid.

[Chalfin]

Guys,

Thanks for all the info. I agree...testing complete, it's time to replace / upgrade the solenoid / controller / wires.