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Old 01-10-2012, 03:43 PM   #1
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Default PDS Troubleshooting

I am responsible for repairing a 2002 PDS Ezgo cart which was running but has now quit. Just before quitting completely, the cart would sometimes take two or three pushes on the accelorator pedal before the motor would engage. I convinced my boss that we should replace all the batteries as they were at least 5 years old when we bought the cart. All the batteries have been replaced and still the cart will not operate. I hear one click from the solenoid when the ignition is turned on and the gas(?) pedal is pressed. I was hoping to find a troubleshooting chart similar to the one on the forum for the DCS carts, but for the PDS carts. Does someone have a troubleshooting sequence that I can use? Thanks in advance for any help you can provide.
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Old 01-10-2012, 06:23 PM   #2
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Default Re: PDS Troubleshooting

There should be information on this in the sticky's. Let me see if I can hunt it down, and you do the same
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Old 01-10-2012, 06:32 PM   #3
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Default Re: PDS Troubleshooting

PDS solenoid activation
Power starts on the White wire on the 36+ of the battery pack.
Power travels to the charger receptacle, goes through a reed switch inside the receptacle and comes out on the red 12 gauge red wire.
The red wire travels back through the loom into controller molex connector at pin 4, out of pin9 to the keyswitch and back in pin 8, out pin 1 to the directional toggle switch & back in pin 3 or 4.
Finally coming out pin 7 to positive side of the solenoid activation circuit. (yellow)
The negative side of the solenoid activation circuit is out of pin #6 (blue)

The peddle micro switch is a separate control circuit at controller plug J4 basically red to switch and green back.
The Run/Tow switch is also a separate control circuit.
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Old 01-11-2012, 08:38 AM   #4
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Default Re: PDS Troubleshooting

Here's a link to the Sticky: with manuals for your cart.
Basic Ezgo electric golf cart wiring and manuals
Download the *.pdf files for Owner, Service and Parts manuals.

There is a PDS troubleshooting tree in the Service manual.

With the key on, F/R switch in F or R, the solenoid should click (clunk) when throttle pedal is pushed.
If it doesn't, check the red wire coming out of the cart's charger receptacle for battery pack voltage.
If it clicks every time pedal is pushed, but cart doesn't always move, you might have a bad controller, or solenoid (main contacts bad), or bad high current cable or connection, or bad ITS (throttle system).

Remember to put Run/Tow switch inb Tow position whenever you disconnect or reconnect a wire or cable. Otherwise you'll destroy the controller.

If you failed to do so while replacing batteries, I suspect the controller is bad.

Also, check out this website for breaking in the new batteries properly.
http://www.cartsunlimited.net/Batter...n_Methods.html
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Old 01-11-2012, 08:42 AM   #5
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Default Re: PDS Troubleshooting

Here are what JohnnieB is telling you to get. Save them to your PC. Everything you need is in them.

Owners Manual for some newer electric carts


Owners Manual for some newer electric carts
http://products.jacobsen.com/img/man...645-g01-gb.pdf

Technician's service and repair manual electric carts
http://products.jacobsen.com/img/manuals/28646.pdf

Service Parts Manuals electric carts
http://products.jacobsen.com/img/manuals/28789-g01.pdf
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Old 01-11-2012, 09:27 AM   #6
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Default Re: PDS Troubleshooting

Spawn, your link to the Owner's manual isn't working.
The other two do, so I don't think it's my 'puter.
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Old 01-11-2012, 09:30 AM   #7
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Default Re: PDS Troubleshooting

404 NOT FOUND on the top link
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Old 01-11-2012, 09:41 AM   #8
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Default Re: PDS Troubleshooting

works now
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Old 01-11-2012, 10:23 AM   #9
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Old 01-11-2012, 03:40 PM   #10
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Default Re: PDS Troubleshooting

To Coltf1991, JohnnieB, Spawn and all the other folks who provided info and links, thank you very much! This info will help me find and hopefully correct the problems.
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