2001 E-Z-GO TXT 36v Solenoid / Diode / Resistor?

[sxecrew]

I recently purchased a 2001 E-Z-GO TXT - PDS 36v electric cart.

I replaced all the batteries, and went for the first ride, and slow motion!

The diagnostics gave me 3-2 code (welded solenoid)
So i ordered a new one, and installed it today..

Still slow motion!

So just for quick test, i disconnected the 250 ohm resistor, and whoo-hoo it works great..

So i would like to order the proper resistor, and diode if needed.

The picture attached shows a Dale CW-5 250 Ohm Resistor. This was going across the big terminals. Everywhere i look, this is a 5 watt 250 ohm resistor. Can i use the 10w instead?

I did not have anything across the small terminals, is something suppose to go there? If so, what would it be?

any links or websites to buy from would be a great help as well

Thanks for any help

[whizzo]

yes you can use a 10 watt resistor.

In general there should be a diode across the coil.

Seems some of the smaller solenoids come with a 1 amp diode, but a 3 amp diode will work fine and is probaly a beter idea......you need to get the diode the right way round......stripe to positive.

cheers

[sxecrew]

awesome, thanks for the info

[simple man]

I don't understand how the resistor could make the cart slower? It's only purpose is to charge the filter capacitors in the controller. This prevents arcing when the solenoid contacts close. Basically, your solenoid lasts longer!

[JohnnieB]

Originally Posted by simple man

I don't understand how the resistor could make the cart slower? It's only purpose is to charge the filter capacitors in the controller. This prevents arcing when the solenoid contacts close. Basically, your solenoid lasts longer!

Actually it is the PDS controller that is making the cart run slower, due to it thinking the solenoid contacts are welded closed.

What is happening is the controller is comparing the voltage on J1 Pin-5 to the voltage on the controller's B+ terminal. Since the controller controls the energizing and de-energizing of the solenoid, it knows when the contacts ought to be open or closed and if the voltage on the B+ terminal doesn't decrease by at least 3-5 volts when they open or doesn't go from a lower voltage to nearly the same voltage on both when closed, it assumes the solenoid contacts are welded (3-2 beep code), and goes into a reduced performance mode.

It might be a bad resistor (Too low of an Ohmic value ?), but I lean more towards a bad high current cables/connections between the main B+ terminal on the battery pack and the Battery side terminal on the solenoid, OR the wires/connections between the Battery side terminal and J1 Pin-5.

[simple man]

That explains it John! My feeble mind is stuck on series carts!

[JohnnieB]

Yep, a PDS controller is a different breed of cat.

I'm speculating, but I suspect they used a 4 bit microprocessor, since the are 15 error codes, plus normal operation, making 16, which is the max count with 4 bits.

Fifteen error codes aren't actually needed, but they were available, so they used them and some of the conditions that triggered errors, weren't thought all the way through.

[sxecrew]

like JohnnieB said, the bad resistor makes the solenoid thinks its welded, and put the cart into limp mode (3 mph limit)

Once i disconnected the resistor, the cart went back to full speed.

I don't know why the diode wasn't installed, but i have ordered a new resistor and new diode, and will install this weekend

I will upload a picture once complete

[JohnnieB]

Originally Posted by sxecrew

like JohnnieB said, the bad resistor makes the solenoid thinks its welded, and put the cart into limp mode (3 mph limit)

Once i disconnected the resistor, the cart went back to full speed.

I don't know why the diode wasn't installed, but i have ordered a new resistor and new diode, and will install this weekend

I will upload a picture once complete

Re-read the bottom line on post# 5

Let us know if the resistor fixes the problem.

-------
EZGO didn't install diodes across the solenoid coil in PDS carts.
The PDS controller feeds both sides of the coil and has internal spike protection.
However, it doesn't hurt to install the diode.

[sxecrew]

everything is installed and up and running.

Got the new resistor in.

JohnnieB, i did check the B+ - To solenoid wire, the wire was in good condition, but the B+ side had a little wiggle in the crimped connector. I crimped that a little harder so there was no wiggle, installed the new resistor, and it runs great.

So i'm not sure if it was the connection or a bad resistor, but its good to go now!

Once i find my multimeter i will test the old resistor to get a final verdict.

Could it have been just the connection? it was tight enough that i couldn't pull the wire out, but loose enough to see the wire strands move slightly as i bent the wire back and forth...