08 ergo pds problem

Jmelder

I have a 2008 ezgo cart f/r switch on dash. Cart power and speed about half turn key off and back on while rolling everything go to normal for a while. What causes this problem

BGW

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JohnnieB

Could be several things, put the controller into diagnostic mode and it may beep an an error code telling you why it is in a reduced performance mode.

The text at the bottom of the attached label tells you how to get into the diagnostic mode and also lists the error codes.

Let us know what you find and we'll proceed from there.

Attached Images

PDS Label on Controller Cover.JPG (142.9 KB, 0 views)

Jmelder

Before it would stop when you drove slow for a mile or so

Jmelder

Before it would stop when you drove around real slow for mile or so. Then you turn key off for 30 sec. Back on problem fixed

JohnnieB

That suggests the controller is overheating.

Driving the cart in diagnostic mode could positively identify if that is, in fact, the problem.

Driving a PDS cart slowly (<5MPH) for extended distances can overheat the stock controller. If the tires are taller than stock (18"), a stock PDS controller in more persnickety about creeping along slowly.

Jmelder

Put controller in diagnostic got 3 beeps with key off but turn key on after test and get 3 space 2 what is this

JohnnieB

The first set of beeps when the controller goes into diagnostic mode tells you what PDS performance mode the controller is in. Three beeps is the Mild-Hill mode.

The error codes are listed on the PDS label I posted earlier in this thread. The 3-2 code is for welded solenoid contacts.

Check the voltage on the controller side large terminal on the solenoid. It should be full battery pack voltage when pedal is pressed and about 3V to 5V less than full battery pack voltage when the pedal is up.

If that checks out okay, measure the voltages on J1-Pins 4 & 5. The should both be at full battery pack voltage. (Pin-4 may be zero volts if battery charger is plugged into cart, but full pack voltage when charger is disconnected from cart.)

Jmelder

If solenoid is welded why does it get better when u switch key on and off while rolling sometimes

JohnnieB

The solenoid may not be welded, having less than full battery pack voltage on J1 Pins 4 & 5 can cause the 3-2 error code, or less than full pack voltage on all four of the pins in J3 might do it. Or the controller might be going bad.

When you turn the key off and back on, you reset the controller and it will run normally until it sees another error situation occurs.


The controller in a PDS energizes and de-energizes the solenoid, so it knows when the solenoid contacts should be closed.

The computer inside the controller senses the battery pack voltage via either J1 Pin-5, or J1 Pin-5, or possibly it looks at what is called Auxiliary Voltage (The voltage that is fed to the external switches) after it goes out to the Run/Tow and comes back. Wherever and however it senses the battery pack voltage, it compares it to the voltage on the controller's B+ terminal, which should be equal to the pack voltage when the solenoid in energized and less than pack voltage when it isn't energized.

If the voltage on the controller's B+ terminal is not below the Auxiliary voltage, than a 3-2 error is generated. The tricky part is that the computer in the controller doesn't know if the voltage on the B+ terminal is staying high, or if the Auxiliary voltage is low.

Check the voltage on all the wires highlighted in red on the attached schematic. They should all be FULL pack voltage, whatever the pack voltage is at the time.

IE: If the voltage between the main positive and main negative battery terminals is 38.2V, than all the red wires should measure 38.2V.

Attached Images

Wiring Diagram - PDS - Solenoid activation traced.jpg (69.7 KB, 0 views)