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Old 12-20-2013, 11:18 PM   #1
wrongway
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Default need help with 2007 pds cart

I'm working on a 2007 pds cart. I need help with order of testing procedures. 36.8 pack voltage. solenoid does not click. Resistor tests good. What should I check next?
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Old 12-21-2013, 07:18 AM   #2
JohnnieB
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Default Re: need help with 2007 pds cart

The resistor has nothing to do with whether the solenoid slicks or not and the system will work with out without the resistor, but the solenoid contacts last longer with it.

The controller supplies both B+ and B- to the solenoid coil and getting it to click is a two step process.

First, to get the controller to apply B+ to one side of the solenoid's coil, you have to have the Charger plug disconnected from cart, Run/Tow switch in RUN, Keyswitch ON and F/R switch in either F or R.
When those conditions are met, you should have Battery pack voltage on the following:
J1 Pins 1, 2 or 3 (R or F), 4, 5, 8 & 9
J3 Pins 1, 2, 3 & 4
If so, you should have B+ on J1 Pin-7.
If the solenoid coil is good, you will also measure B+ on J1 Pin-6.

Second, The pedal switch has to close, telling the controller to apply B- to J1 Pin-6.
With Pedal switch closed, you should have pack voltage on J2 Pins 1 & 2
If so, J1-pin-6 should drop to zero (B-) and the solenoid should click.
Attached Images
File Type: jpg Wiring Diagram - PDS - Solenoid activation traced.jpg (69.7 KB, 0 views)
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Old 12-21-2013, 11:19 AM   #3
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Default Re: need help with 2007 pds cart

Thanks JohnnieB, I'll get some readings and post the results.
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Old 12-21-2013, 08:41 PM   #4
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Default Re: need help with 2007 pds cart

only shows voltage on J1 pins 4,5 and 10
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Old 12-22-2013, 07:31 AM   #5
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Default Re: need help with 2007 pds cart

Ouch.

With pack voltage on J1 Pins 4 & 5, you should also have voltage on J3 Pins 1 & 3.

The good news is that an Alltrax DCX400 Controller will give you about 24 MPH on stock height tires with a 36V battery pack.
http://www.cartsunlimited.net/Custom_Options.html
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Old 12-22-2013, 07:59 AM   #6
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Default Re: need help with 2007 pds cart

I though it was time for a new controller, just wanted to be sure before I spent the money.
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Old 12-22-2013, 08:21 AM   #7
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Default Re: need help with 2007 pds cart

Since the controller is "dead" anyway with no power coming out of pin 1 to feed back into the controller via the f&r switch, I wonder what would happen if you just jumpered power to pin 1 to "simulate" the controller working?

I suspect the driver circuit out of pin 1 is dead so giving the f&r an external power source may make it work again till you can get another controller. Seems to me you can't kill a dead controller so it's worth a try.
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Old 01-17-2014, 04:45 PM   #8
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Default Re: need help with 2007 pds cart

Just an update. It was a bad controller. Replaced the controller and everything operates as it should. Thanks for the help.
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Old 01-17-2014, 06:11 PM   #9
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Default Re: need help with 2007 pds cart

Thanks for the feedback. Glad that you got it going.
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