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Electric EZGO Electric EZ GO Marathon, Medalist, TXT and RXV.



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Unread 02-14-2018, 02:15 PM   #1
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Join Date: Feb 2018
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Default Ezgo pds - won't go 1-4 error code

Hello EZ goers, I am new to the site.

I need some help getting my EZGO PDS going again. It won't go forward or backwards - intermittently. You can hear the micro switch click in the pedal box. ( I have checked the micro switch and it is good ) But the solenoid doesn't click ( intermittently ) when the solenoid clicks the cart goes and when it doesn't click it don't go. It is more like a thump than a click.
I have replaced the solenoid and it is new. Once the cart stars going you are ok until you park it for a few min. and then it is likely not to go. Pumping the pedal several time might get you going and then it might not.

Looking up the fault code it reads: High Pedal Disable

The error code chart is on page 3 of the SM

It is hard to troubleshoot because you get started and then the thing starts going again. It would be far better if it was just dead and would not go at all.

I have been through most of the flow charts and it doesn't seem to be a connection. I have replaced the solenoid and I have bypassed the Run/Tow
switch as I thought is was a bit flakey but it is now bypassed to the Run mode and it is still giving me the 1-4 code and when you get that code the solenoid will not engage. I am suspecting that the problem is in the Pedal box with the linkage or adjustment. I have attached a photo of my pedal box and ITS

Page F-21 of the SM shows how the Pedal Box - micro switch - plunger and ITS should be set up and my box is not set up that way. The gap between the plunger and the opening of the ITS is much larger. I tried to adjust that but it will not adjust to a gap that small. There is a adjustment it the linkage under the floor board but it doesn't look as if it has slipped or something. I am going to try the linkage adjustment soon. The example of the plunger shows that the gap is suppose to be the size of a 7/32 drill bit and my gap is much larger.

I was going to post a link to the S/M that I am using but the site says I have to be a member for 7 days. I will come back in 7 days and add the link even if I get the problem solved.

Thanks in advance to anyone who wants give some suggestions.

Ricky


CCI02142018.jpg

PEDAL BOX.jpg

Ole Miss golf cart.jpg

KEY AND F R SWITCH.jpg
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Unread 02-14-2018, 02:50 PM   #2
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Default Re: Ezgo pds - won't go 1-4 error code

You might have found the trouble if the micro switch (ms) trigger is rolling off the shoulder on the plunger when the pedal comes up sometimes.
Release the plunger lock nut & turn the plunger counterclockwise until the plunger sits on the shoulder, tighten the lock nut and test the cart.
The gap between the plunger and the tunnel only needs to be 1/4 or more.
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Unread 02-14-2018, 03:33 PM   #3
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Default Re: Ezgo pds - won't go 1-4 error code

Thanks Scottyb - I will check the position of the micro switch lever on the plunger.
Thing is, there is no way that the plunger after unlocking the lock nut will adjust out to give me the suggested gap between the plunger and the opening in the ITS like the drawing shows. I have already tried it. Let it all the way out and still larger gap than the drawing shows.
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Unread 02-14-2018, 03:51 PM   #4
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Default Re: Ezgo pds - won't go 1-4 error code

Have you downloaded the Service Manual? It gives a detailed explanation on adjustment, and there are several.
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Unread 02-14-2018, 05:15 PM   #5
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Default Re: Ezgo pds - won't go 1-4 error code

Quote:
Originally Posted by RCRICK00 View Post
Thanks Scottyb - I will check the position of the micro switch lever on the plunger.
Thing is, there is no way that the plunger after unlocking the lock nut will adjust out to give me the suggested gap between the plunger and the opening in the ITS like the drawing shows. I have already tried it. Let it all the way out and still larger gap than the drawing shows.
Please re read my post - the answer you are looking for may be there.
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Unread 02-14-2018, 09:01 PM   #6
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Default Re: Ezgo pds - won't go 1-4 error code

Thanks again, Notice in my photo of the cam, plunger and ITS. My cam only has one lock nut. Not two like in the SM drawing. When I would turn the nut the cam and plunger would also turn. I got a pair of plyers and held the cam and then I see that the plunger and the cam screws separately.
I adjusted the plunger out so that it was about 1/4 from going in the ITS, but this makes everything loose. I test drove the cart anyway and with it adjusted with the MS where it suppose to be and the plunger where it is suppose to be the cart starts out really fast but as you push the pedal further down it slows down and you get a 1-2 error code.
Apparently my cart had been running fine for the last 6 years with the plunger 1/2 inch from the ITS.
Also I notice not that I have been working on it that the acceleration is real jerky.
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Unread 02-14-2018, 10:37 PM   #7
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Default !

Quote:
Originally Posted by RCRICK00 View Post
Thanks again, Notice in my photo of the cam, plunger and ITS. My cam only has one lock nut. Not two like in the SM drawing. When I would turn the nut the cam and plunger would also turn. I got a pair of plyers and held the cam and then I see that the plunger and the cam screws separately.
I adjusted the plunger out so that it was about 1/4 from going in the ITS, but this makes everything loose. I test drove the cart anyway and with it adjusted with the MS where it suppose to be and the plunger where it is suppose to be the cart starts out really fast but as you push the pedal further down it slows down and you get a 1-2 error code.
Apparently my cart had been running fine for the last 6 years with the plunger 1/2 inch from the ITS.
Also I notice not that I have been working on it that the acceleration is real jerky.
Adjust it someplace in between - In fact stop looking at the gap - It's not critical!


Simply adjust until the ms works as designed every time.
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Unread 04-18-2018, 06:36 PM   #8
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Default Re: Ezgo pds - won't go 1-4 error code

Hello Guys - I have updates on my problem. I finally gave up and took my Ezgo to a big repair shop. The shop said that they could never get the cart to fail but they said that my batteries were near the end of their life. I knew this as they were 2012's and were pretty weak. So I let them replace the batteries and the battery cables. They said that they tried the cart 12 times after the work and it never failed.
I picked up the cart and it failed after just riding it 2 times. Since they only charged me for the batteries and about 60.00 for labor, I decided to take it to another big shop that was closer to me.
The second shop said that the cart did fail as it wouldn't run when I dropped it off. Same problem. Micro switch in pedal box clicked but the solenoid would not engage
They said that they replaced the ITS sensor and everything was good now. I ask them to try the cart at least 4 more times and to make sure the pedal control was smooth.
I went to pick up my cart and I noticed they had left nuts and washers laying on the
floor board of the cart. I picked them up and put them in my pocket.
I got the cart home after having a blowout on a tire of the borrowed trailer.
The cart failed after just riding it 2 or 3 times. This time it is different. When it fails it will only go about 1 mile an hour. Super slow. The solenoid is engaging now but the speed is only about one mile an hour and it is making a shuddering feel.
I tried flipping the run/tow switch a couple times and it started going good again but then it slowed down to a crawl after about 1/4 mile. Intermittent again but different.
Knowing that extra nuts and washers were laying on my floor board and they looked like the nuts that go on the solenoid, I decided to take the cover off the controller and have a look. First thing I noticed is that they left 1 of the 4 screws out of the cover. You would know it is the hard to get to one. Then I noticed that they cut out the resistor across the solenoid and the diode as well. I found the resistor laying on the floor under the cover.
I called the shop and ask them if they had done some kind of mod. that you don't use the resistor and diode with the new ITS. The owner of the shop said that " no they do that on all the Ezgos as the resistor and diode was not needed and was just a source of trouble." I don't believe that as I know that they don't put components in these machines if they don't serve a purpose. I reconnected the resistor and it did not help the problem. I did not find the diode.
I don't know what they have done to my cart but I know that I got ripped off.
If anyone can make any suggestions as what might be the problem I would surely appreciate it as I don't wont to fool with those guys again and it is so much trouble to take the cart 40 miles to a shop. They charged me 200.00 and I bet they are lying about
replacing the ITS. I am going to call them tomorrow and tell them I want my old ITS and my diode.

Thanks

Ricky
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