2007 controller problems

gale · 05-20-2013, 07:14 AM

I have a 2007 PDS cart. Thru a series of mistakes, I am about to install my 3rd controller. First was trying to pull something heavy across the yard. 2nd was forgetting to switch to tow before plugging in the 10 pin connector. (arced and melted a terminal). The last controller I put on was a rebuilt unit. All went well until I pushed down on the accellerator. Something "popped" & smoke came out of the controller. Before I try again, is there anything that would cause that other than maybe a bad rebuild? Motor checked OK. Solenoid is good. FnR switch, run/tow switch, ITS, and wiring are all good. all connections are clean and tight. ANY help would be greatly appreciated.

JohnnieB · 05-20-2013, 07:52 AM

What size tires do you have?
Tall tires take more amps to turn and anything over stock height (18") is hard on a stock PDS controller.

Might be a good time to upgrade to an aftermarket controller.

gale · 05-20-2013, 08:16 AM

The cart is all stock. Tires etc. are all OEM, with the exception of an extra battery connected to a solar panel to power lites, horn, etc. It is not connected to any part of the carts wiring.

scottyb · 05-20-2013, 08:22 AM

Post pic showing all of the wiring connections before you try to go.
Sometimes we can see a problem this way. Also stop messing around with 'rebuilt' controls and get an Alltrax control.

gale · 05-21-2013, 06:56 AM

Here is a pic of the solenoid connections.

JohnnieB · 05-21-2013, 07:27 AM

The pre-charge resistor (Brown object connected between the solenoid's two large terminals) appears to have a chunk missing.

That may be the source for the sound and smoke rather than the controller, but what could have possibly caused the resistor overheat?

What is the battery pack voltage?

-----
Need to back off a foot or three to include the main +&- terminals on battery pack.

kgsc · 05-21-2013, 09:52 AM

If the resister is toast it could be a bad solenoid JB. Cart tried to go and all that current tried to go through it = poof

gale · 05-21-2013, 10:03 AM

The resistor was hot @ one time, so I questioned it myself. Un-hooked and ckd. it. Still reading 220 ohms of resistance. I actually saw smoke coming out of the controller @ the 10 pin connector. when this happened.

scottyb · 05-21-2013, 10:27 AM

Time for pkg 808

30% more torque and 24mph on stock tires
On sale with heavy duty solenoid (resistor & diode included)
$499

gale · 05-22-2013, 11:29 AM

Thanks SCOTTYB. Just ordered pkg.#808.

05-20-2013, 07:14 AM	#1
gale Not Yet Wild Join Date: May 2011 Posts: 5	2007 controller problems I have a 2007 PDS cart. Thru a series of mistakes, I am about to install my 3rd controller. First was trying to pull something heavy across the yard. 2nd was forgetting to switch to tow before plugging in the 10 pin connector. (arced and melted a terminal). The last controller I put on was a rebuilt unit. All went well until I pushed down on the accellerator. Something "popped" & smoke came out of the controller. Before I try again, is there anything that would cause that other than maybe a bad rebuild? Motor checked OK. Solenoid is good. FnR switch, run/tow switch, ITS, and wiring are all good. all connections are clean and tight. ANY help would be greatly appreciated.
gale Not Yet Wild Join Date: May 2011 Posts: 5

05-20-2013, 07:52 AM	#2
JohnnieB Techno-Nerd Join Date: Jun 2011 Location: West Virginia Posts: 19,654	Re: 2007 controller problems What size tires do you have? Tall tires take more amps to turn and anything over stock height (18") is hard on a stock PDS controller. Might be a good time to upgrade to an aftermarket controller.

05-20-2013, 08:16 AM	#3
gale Not Yet Wild Join Date: May 2011 Posts: 5	Re: 2007 controller problems The cart is all stock. Tires etc. are all OEM, with the exception of an extra battery connected to a solar panel to power lites, horn, etc. It is not connected to any part of the carts wiring.
gale Not Yet Wild Join Date: May 2011 Posts: 5

05-20-2013, 08:22 AM	#4
scottyb Happy Carting Join Date: Dec 2007 Location: Southern California Posts: 73,753	Re: 2007 controller problems Post pic showing all of the wiring connections before you try to go. Sometimes we can see a problem this way. Also stop messing around with 'rebuilt' controls and get an Alltrax control.

05-21-2013, 07:27 AM	#6
JohnnieB Techno-Nerd Join Date: Jun 2011 Location: West Virginia Posts: 19,654	Re: 2007 controller problems The pre-charge resistor (Brown object connected between the solenoid's two large terminals) appears to have a chunk missing. That may be the source for the sound and smoke rather than the controller, but what could have possibly caused the resistor overheat? What is the battery pack voltage? ----- Need to back off a foot or three to include the main +&- terminals on battery pack.

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05-21-2013, 09:52 AM	#7
kgsc Gone Wild Join Date: Dec 2009 Location: Aiken, SC Posts: 14,247	Re: 2007 controller problems If the resister is toast it could be a bad solenoid JB. Cart tried to go and all that current tried to go through it = poof

05-21-2013, 10:27 AM	#9
scottyb Happy Carting Join Date: Dec 2007 Location: Southern California Posts: 73,753	Re: 2007 controller problems Time for pkg 808 30% more torque and 24mph on stock tires On sale with heavy duty solenoid (resistor & diode included) $499

05-22-2013, 11:29 AM	#10
gale Not Yet Wild Join Date: May 2011 Posts: 5	Re: 2007 controller problems Thanks SCOTTYB. Just ordered pkg.#808.
gale Not Yet Wild Join Date: May 2011 Posts: 5

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