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Old 03-18-2012, 09:00 PM   #1
genesis11
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Default Arcing when connecting the controler

New to the forum, it's a great site with excellent resources! I recently purchased a used 06 EZGO PDS with factory drive components, a lift, & 22" tires. After driving it on mild terrain it quit. I found one of the batter terminals melted were the lug attaches. Found a thread on how to drill & tap it and have done so. when I went to connect the negative side of the controller back to the batteries it arced. This all happened right before I had to come to work on midnight shift. So I am sitting here going nuts wondering what is wrong. I have done not further testing because I had to leave for work. Just wondering what direction I should take first. Any help would be greatly appreciated.
Thanks--Once again, a great site!
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Old 03-18-2012, 09:04 PM   #2
LostHusker
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Default Re: Arcing when connecting the controler

Welcome !!!


Did you flip the tow/run switch to the tow position before working on the cart?
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Old 03-18-2012, 09:04 PM   #3
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Default Re: Arcing when connecting the controler

Welcome to BGW!

There is a Run/Tow toggle switch on the controller cover under the passenger seat. That switch should be set to TOW if you are towing the cart OR performing ANY maintenance to the wiring.
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Old 03-18-2012, 09:06 PM   #4
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Default Re: Arcing when connecting the controler

Welcome to BGW


did you flip the tow/run switch on the controller cover to TOW before you unhooked the battery cable,??
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Old 03-18-2012, 09:09 PM   #5
genesis11
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Default Re: Arcing when connecting the controler

Thanks for the quick response.
I don't remember moving it to the tow position.
I was planning an upgrade--does this mean it will happen sooner than I planned?
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Old 03-18-2012, 09:13 PM   #6
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Default Re: Arcing when connecting the controler

It is a possibility....
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Old 03-18-2012, 09:21 PM   #7
genesis11
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Default Re: Arcing when connecting the controler

Does this mean a new controller? This is going to be awfully expensive rookie mistake. Everything I have read so far - Alltrax seems to be a good upgraded controller. Is there a better one out there?
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Old 03-18-2012, 10:20 PM   #8
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Default Re: Arcing when connecting the controler

Can't go wrong with the corrtect Alltrax unit in your cart. Don't give up hope just yet. When you go back to work on it, switch it to TOW, complete your connections, switch it to RUN, and try it out. Maybe you'll get lucky.
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Old 03-18-2012, 10:33 PM   #9
genesis11
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Default Re: Arcing when connecting the controler

I'm going to try it first thing in the morning. Thanks again for you input.
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