solenoid resistor getting hot

[mlackland]

The solenoid resistor is getting hot. The only way it doesn't get hot is if I unplug F2 from the controller. There isn't any voltage on pin 7. The solenoid comes on when the key is turned on even when not pressing the accelerator. I have replaced both the solenoid and controller, but I can't figure out what is wrong. Anyone here have any ideas?

[JohnnieB]

Originally Posted by mlackland

The solenoid resistor is getting hot. The only way it doesn't get hot is if I unplug F2 from the controller. There isn't any voltage on pin 7. The solenoid comes on when the key is turned on even when not pressing the accelerator. I have replaced both the solenoid and controller, but I can't figure out what is wrong. Anyone here have any ideas?

Welcome to BGW!

Sounds like you have either a PDS or a DCS cart. (IE: F2 terminal on controller)
Have to know which one to troubleshoot.

Solenoid clicking without pressing pedal, typically means the microswitch in the pedal box is bad or maladjusted.

How hot does the resistor get? They typically get warm, but not too hot to touch.

[mlackland]

Originally Posted by JohnnieB

Welcome to BGW!

Sounds like you have either a PDS or a DCS cart. (IE: F2 terminal on controller)
Have to know which one to troubleshoot.

Solenoid clicking without pressing pedal, typically means the microswitch in the pedal box is bad or maladjusted.

How hot does the resistor get? They typically get warm, but not too hot to touch.

Its a DCS and the resistor gets very hot.

[gornoman]

Check the ITS micro switch under the floormat. It might be broken in the closed position.

[JohnnieB]

Gorno is on the right track.

However, it sounds like there is more than just a bad pedal microswitch.

The solenoid clicking when you turn on the key is probably a bad pedal switch.

On the other hand, the resistor getting hot indicates the solenoid contacts are not closed when the controller is being told to pass amps to the motor.

That means the ITS is bad or out of adjustment.

While you are fixing the pedal switch, check the its adjustments.

[mlackland]

Ok, the pedal was out of adjustment. Now the solenoid doesn't click on until I press the pedal. Shouldn't the solenoid click off after letting off of the pedal? The resistor is still getting hot unless the tow switch is on. Thanks much for the quick replies

[JohnnieB]

Originally Posted by mlackland

Ok, the pedal was out of adjustment. Now the solenoid doesn't click on until I press the pedal. Shouldn't the solenoid click off after letting off of the pedal? The resistor is still getting hot unless the tow switch is on. Thanks much for the quick replies

Not instantaneously, but eventually. The controller is what actually activates the solenoid, the pedal switch only tells the controller that you want to activate the solenoid, but not when to deactivate it.

For some reason the controller is passing current with the pedal up. (Solenoid contacts open)

Check the ITS voltages at the controller. See attached

Either the Throttle is telling the controller to pass amps when it shouldn't (ITS issue) or the controller is bad.

What Year and Body style is your cart?

[mlackland]

Originally Posted by JohnnieB

Not instantaneously, but eventually. The controller is what actually activates the solenoid, the pedal switch only tells the controller that you want to activate the solenoid, but not when to deactivate it.

For some reason the controller is passing current with the pedal up. (Solenoid contacts open)

Check the ITS voltages at the controller. See attached

Either the Throttle is telling the controller to pass amps when it shouldn't (ITS issue) or the controller is bad.

What Year and Body style is your cart?

Its a 1996 ezgo txt dcs cart. Ok, so the voltage at pin should be 0 before pressing the pedal correct? It is actually 0.44V before pressing the pedal.

[mlackland]

At pin 1, the white wire, is what I meant.

[JohnnieB]

Originally Posted by mlackland

Its a 1996 ezgo txt dcs cart. Ok, so the voltage at pin should be 0 before pressing the pedal correct? It is actually 0.44V before pressing the pedal.

No, that is not correct. The voltage before the pedal is pushed is not defined.

What is define is the voltage at the instant the pedal microswitch contacts close (making the solenoid click).

Please re-read the instructions in the attachment I posted in post#7.