PDS keeps on reporting WELDED SOLENOID

[Golfdog]

One of my golfing pals has a PDS that keeps on reporting a welded solenoid (diagnostic mode 3-2 beeps) Has now fitted 2 different solenoids and after about 1 1/2 rounds the car goes into limp mode. During the last few holes it will occasionally come rite then go back to limp. I am beginning to suspect that the controller has an issue and senses something that is not there. Any suggestions ?

[LostHusker]

I am guessing the cart is stock?

[Golfdog]

Yes stock cart

[JohnnieB]

Originally Posted by Golfdog

One of my golfing pals has a PDS that keeps on reporting a welded solenoid (diagnostic mode 3-2 beeps) Has now fitted 2 different solenoids and after about 1 1/2 rounds the car goes into limp mode. During the last few holes it will occasionally come rite then go back to limp. I am beginning to suspect that the controller has an issue and senses something that is not there. Any suggestions ?

It is either a bad controller sensing good voltages or it is a good controller and the voltages it is sensing actually are bad.

I'm not sure which two voltages the controller compares, but I am sure one of the two is the voltage at the controller's B+ terminal.
It should have full battery pack voltage when the solenoid contacts are closed and 3-5 volts less when they are open.
Remove the resistor from across the solenoid's big terminals and the voltage will (should) drop to Zero when the contacts are open.

There are upwards of 13 possibilities for the other voltage used for comparison (All the wires highlighted in red on the attached schematic), but my guess would be either J1 Pin-5 or J1 Pin-4. Those two should all have full battery pack voltage on them all the time (expect when a charger is plugged into cart on J1 Pin-4).

If the voltages are right, the controller is bad.

[Golfdog]

Tks Johnnie, will help him do some tests over the weekend.