my 2004 36V PDS

twilliams81 · 08-03-2017, 02:44 PM

I am having a very hard time with this cart. I got this and it's a very good looking and clean cart, lifted, lights, backseat, radio, etc. It wasn't moving and not even a solenoid click. Had some suspicions that it could be the motor so I pulled and sure enough there was a wire burned off of the brush assembly so I repaired that and replaced the brush assembly. Got it back on and still nothing; so i said the hell with it and ordered a brand new stock replacement motor and put it on and again..nothing. So I decided to replace the solenoid...still nothing...then the controller... and with one quick push of the pedal POP! there went the controller. So got another controller and another solenoid and now I'm getting a solenoid click as soon I put it into forward or reverse. The controller is toning out 2-4 and I've gone through all the corrective actions (that really doesn't help btw) and I'm still only getting a solenoid click with the F/R switch ONLY and NOTHING with the PEDAL and still no movement out of the cart. I'm growing incredibly frustrated with this so any help would be greatly appreciated.

***I'd be happy to send any pictures anyone might need to see just let me know!

scottyb · 08-03-2017, 03:20 PM

Check the pedal box micro switch if it's good check the 4 pin connector between the pedal box and the controller

ARKSoft84 · 08-03-2017, 03:25 PM

You'll need a large treadmill and a fork-lift!

It would probably be a good idea to go ahead and get a battery measurement so that we know that you are working with fully charged batts.

twilliams81 · 08-03-2017, 03:26 PM

I've got continuity in the micro switch but what exactly should I be looking for in the connections between?

twilliams81 · 08-03-2017, 03:33 PM

I've got 37.8 at the moment

twilliams81 · 08-03-2017, 03:40 PM

I've also got full continuity on all wires coming from pedal box up to my controller. This all makes absolutely no sense...

twilliams81 · 08-03-2017, 03:59 PM

Even with the pedal box harness unplugged from J4 I am still getting a solenoid click with the F/R switch and the key on.

twilliams81 · 08-03-2017, 04:46 PM

Quote:

Originally Posted by ARKSoft84

You'll need a large treadmill and a fork-lift!

It would probably be a good idea to go ahead and get a battery measurement so that we know that you are working with fully charged batts.

No what I probably need is a club car or GAS!! LoL

twilliams81 · 08-04-2017, 07:56 AM

I guess that's all I can get...well you guys tried and still no luck I might be selling this pile very cheap and soon! Any takers?

scottyb · 08-04-2017, 08:20 AM

The solenoid needs 36v between the 2 small solenoid posts when you press the gas. the + side comes from the pedal switch and the - side from the controller.
See which one is missing.
If missing the pedal side (+) retrace your previous steps.
If missing the controller side (-) as I suspect, replace the wire with a single lead to the battery main (-). And stop wasting $ on repaired controllers.

08-03-2017, 02:44 PM	#1
twilliams81 Gone Wild Join Date: Aug 2016 Posts: 612	please help me chase the gremlins out of my 2004 36V PDS I am having a very hard time with this cart. I got this and it's a very good looking and clean cart, lifted, lights, backseat, radio, etc. It wasn't moving and not even a solenoid click. Had some suspicions that it could be the motor so I pulled and sure enough there was a wire burned off of the brush assembly so I repaired that and replaced the brush assembly. Got it back on and still nothing; so i said the hell with it and ordered a brand new stock replacement motor and put it on and again..nothing. So I decided to replace the solenoid...still nothing...then the controller... and with one quick push of the pedal POP! there went the controller. So got another controller and another solenoid and now I'm getting a solenoid click as soon I put it into forward or reverse. The controller is toning out 2-4 and I've gone through all the corrective actions (that really doesn't help btw) and I'm still only getting a solenoid click with the F/R switch ONLY and NOTHING with the PEDAL and still no movement out of the cart. I'm growing incredibly frustrated with this so any help would be greatly appreciated. ***I'd be happy to send any pictures anyone might need to see just let me know!
twilliams81 Gone Wild Join Date: Aug 2016 Posts: 612

08-03-2017, 03:20 PM	#2
scottyb Happy Carting Join Date: Dec 2007 Location: Southern California Posts: 73,419	Re: Please help me exorcise the demons in my 2004 36V PDS Check the pedal box micro switch if it's good check the 4 pin connector between the pedal box and the controller

08-03-2017, 03:25 PM	#3
ARKSoft84 Gone Wild Join Date: Jun 2017 Location: NC Posts: 368	Re: Please help me exorcise the demons in my 2004 36V PDS You'll need a large treadmill and a fork-lift! It would probably be a good idea to go ahead and get a battery measurement so that we know that you are working with fully charged batts.

08-03-2017, 03:26 PM	#4
twilliams81 Gone Wild Join Date: Aug 2016 Posts: 612	Re: Please help me exorcise the demons in my 2004 36V PDS I've got continuity in the micro switch but what exactly should I be looking for in the connections between?
twilliams81 Gone Wild Join Date: Aug 2016 Posts: 612

08-03-2017, 03:33 PM	#5
twilliams81 Gone Wild Join Date: Aug 2016 Posts: 612	Re: Please help me exorcise the demons in my 2004 36V PDS I've got 37.8 at the moment
twilliams81 Gone Wild Join Date: Aug 2016 Posts: 612

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08-03-2017, 03:40 PM	#6
twilliams81 Gone Wild Join Date: Aug 2016 Posts: 612	Re: Please help me exorcise the demons in my 2004 36V PDS I've also got full continuity on all wires coming from pedal box up to my controller. This all makes absolutely no sense...
twilliams81 Gone Wild Join Date: Aug 2016 Posts: 612

08-03-2017, 03:59 PM	#7
twilliams81 Gone Wild Join Date: Aug 2016 Posts: 612	Re: Please help me exorcise the demons in my 2004 36V PDS Even with the pedal box harness unplugged from J4 I am still getting a solenoid click with the F/R switch and the key on.
twilliams81 Gone Wild Join Date: Aug 2016 Posts: 612

08-04-2017, 07:56 AM	#9
twilliams81 Gone Wild Join Date: Aug 2016 Posts: 612	Re: my 2004 36V PDS I guess that's all I can get...well you guys tried and still no luck I might be selling this pile very cheap and soon! Any takers?
twilliams81 Gone Wild Join Date: Aug 2016 Posts: 612

08-04-2017, 08:20 AM	#10
scottyb Happy Carting Join Date: Dec 2007 Location: Southern California Posts: 73,419	Re: my 2004 36V PDS The solenoid needs 36v between the 2 small solenoid posts when you press the gas. the + side comes from the pedal switch and the - side from the controller. See which one is missing. If missing the pedal side (+) retrace your previous steps. If missing the controller side (-) as I suspect, replace the wire with a single lead to the battery main (-). And stop wasting $ on repaired controllers.

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