Hello, New to Forums

[frnresq911]

Hello to everyone, im new to the forums. Have been working on my first cart build over the winter. These are fun and interesting. Got new batteries today but cant seem to get anything to work. Its a 2002 EZGO PDS, turn the key on and nothing. Not sure where to go from here, been reading alot of posts. The Controller looks brand new. When i turn the key and push the gas the resistor on the solenoid get very hot and starts to smoke. Not sure if someone wired it wrong before me. Would really appreciate any help anyone can give.

Thanks in advance.

[frnresq911]

Not sure if this is wired correctly so i snapped a pic of it.

[RESCUEMEDIC13]

Welcome to the forum! Click on EZ-GO electric click the sticky to find your correct wiring. Hope this helps

[RESCUEMEDIC13]

http://www.buggiesgonewild.com/elect...g-manuals.html

[frnresq911]

thank you, looking at it now

[Great white north]

Do you hear the solenoid click when depressing the gas ?

[frnresq911]

No, just started smelling some smoke so i shut everything off.

[JohnnieB]

Sounds like the controller is passing amps to the motor, but the solenoid isn't closing, so they are being drawn through the pre-charge resistor and heating it up.

The controller controls both B+ and B- to solenoid, so it could be a bad controller, or a bad solenoid coil, or bad Yellow or Blue wires on the small terminals on the solenoid.

Connect DVM negative test lead to main negative terminal on battery pack.
With Run/Tow in RUN, Keyswitch ON and F/R in R, connect the DVM positive test lead to the solenoid's small terminal with Yellow wire attached.
It should read B+ (Battery pack voltage)
If not, the controller may be bad, but need to check some other voltages to be sure.

If you do have B+ on Yellow wire, connect the positive test lead to small terminal with Blue wire.
It should also read B+.
If not, the solenoid coil is bad.

If it also has B+, press the pedal.
The voltage should drop to zero.
If not, the controller may be bad, but need to do some more voltage checks to be sure.

Here is a PDS schematic showing all the places that B+ must be present to activate the solenoid.

[frnresq911]

Thank you for your response..i did the checks u said to and im getting B+ from both connections on solenoid but doesnt drop to zero when depress pedal and probe on blue side

[JohnnieB]

Check the voltage at J4 Pin-1 (with all plugs plugged in)
Should be Zero with pedal up and B+ with pedal down. (That is the last step in a chain of events that tells the controller to activate the solenoid)

If not, the pedal microswitch (or connecting wiring) is bad. (Microswitches are high failure items)

If so, the controller is probably bad, but I'd check for B+ on all the wires highlighted in red on the schematic I posted.

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Be sure to place Run/Tow switch in TOW before disconnecting or reconnecting any wires.

If any of the voltages are missing, you can check most of the switches by disconnecting the various plugs and measuring between the respective pins which an ohmmeter.