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Old 05-04-2016, 05:50 AM   #1
BCGC
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Default Hot resistor

2003 PDS not running and resistor getting hot , no solenoid click, code on cart said low voltage but have 38+ at batteries and solenoid. Was told to unhook the A1 and see if it still gets hot and it still got hot, told it might be a short in the motor. Would like to see if there are some test I can try before removing the motor.
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Old 05-04-2016, 08:40 AM   #2
JohnnieB
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Default Re: Hot resistor

Not sure where your technical consultant learned troubleshooting, but if you disconnect the A1 cable and the resistor still gets hot, than the problem is not the motor.

The resistor gets hot because:
1. The solenoid's contacts are not closing and the motor is trying to draw up to 300A through a 250Ω resistor.
2. The controller's innards are shorted and excessive current is being drawn through the 250Ω resistor.
3. Short somewhere in the high current circuit.

Get the solenoid to click when it should and go from there is need be.

First check the voltage on J1 Pins 4 and 5.
Pin-5 should be full battery pack voltage (38+V) at all times and Pin-4 should be when charger is not plugged into cart.

Once you get full battery pack voltage on both of those pins, then check for full battery pack voltage on all the wires highlighted in red on attached schematic.
Attached Images
File Type: jpg Wiring Diagram - PDS - Solenoid activation traced.jpg (69.7 KB, 0 views)
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Old 05-04-2016, 09:12 AM   #3
scottyb
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Default Re: Hot resistor

Stick with BGW, the advice floating around 'out there' is laughable at times.
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Old 06-03-2016, 05:51 AM   #4
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Default Re: Hot resistor

Up date on cart controller replaced (bad field) and motor checked by shop (good), installed and no power out of controller sent it back for rebuild. They sent me a different controller and told me there were several items wrong with the one I sent back it had bad solenoid driver, blown Tow/ Run path and a bad reverse diode. Not sure if I want to install the controller due to it not being covered for replacement. Pulling hair out.
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Old 06-03-2016, 08:30 AM   #5
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Default Re: Hot resistor

Stop messing around with repaired controls and buy an XCT control with the industry's best tech support and 2 yr warranty - you'll be glad you did
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Old 06-03-2016, 09:06 AM   #6
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Default Re: Hot resistor

Sounds like you are now between a rock and a hard place for whatever you paid for the rebuilt controller. More correctly, a repaired controller.

Basically, all the components in a "rebuilt" controller are the same age, have been exposed to the same environmental conditions and have the same operating hours as the first component(s) that failed and were replaced, so the probability of the components not replaced failing is high.

If the cart ran before the problem(s) with the original controller, the control wiring ought to be okay.

If a diode was installed backwards across the small terminals on the solenoid, it might take out the solenoid driver circuits in the controller.

Leave the diode off when you try it.

---------
I agree that an XCT would be the best answer.
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Old 06-04-2016, 03:21 PM   #7
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Default Re: Hot resistor

Thanks for the information thought about the diode will try and if it fails again will get a new controller.
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Old 06-07-2016, 08:52 AM   #8
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Default Re: Hot resistor

Hooked up and did not even get power out of the controller, did get a small spark on the Battery neg post when hooking it up.
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