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Old 05-28-2014, 09:11 PM   #1
jellyroll22
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Default 07 PDS EZGO -- no go

I am trying to help a buddy with his 07 ezgo PDS. Since we live in MI, and this winter was silly cold, he had a battery freeze. He had a second that didn't test well so two were replaced of the 6. The other 4 appear to be in good shape. The pack currently tests at 36.3 volts. When I checked it out I found the B+ wire connected to the neg post of the pack with the B- wire. I fixed that with the help of the wiring diagrams in the stickes.

SYMPTOMS:
The charger won't come on.
Solenoid doesn't click.
Cart won't move (it's in 'run')

What I have done:
I thought with the charger problem it may be the reed switch. Checked and it's all good.

Confirmed entire cart is wired properly.
I tried the diagnostic function of the cart but it doesn't beep or act like it is working. Wondering if him hooking up battery pack wrong smoked controller enough that this function won't work.

I tried searching but didn't find any good diagnostic threats that really helped.
Ideas???????? Thanks in advance!
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Old 05-28-2014, 09:21 PM   #2
scottyb
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Default Re: 07 PDS EZGO -- no go

The charger needs to see about 24-28v to come on.... test the receptacle to see how much voltage the charger is seeing.....

Worse case you can hot-wire the charger for an hour of full blast charging... then put it back and charge as normal. My guess is your battery woes aren't over yet.
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Old 05-30-2014, 04:35 PM   #3
jellyroll22
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Default Re: 07 PDS EZGO -- no go

I checked the charging receptacle and got 36.2. When I plug the power wise q e digital charger in, it flashes 6 red blinks, which according to the charger indicates a fault. When checking the 2 large posts on the solenoid I get the same 36.2 reading but no clicks no matter what I try. In checking the batteries individually I get 6.2 for each except one which I get 5.1. So, two questions I guess. Could one battery being that far off of the others cause me these problems? #2 why no solenoid click like it's working? Ok, 3 I guess. If the charger is seeing 36.2 volts, why doesn't it come on?
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Old 05-30-2014, 07:14 PM   #4
radioman
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Default Re: 07 PDS EZGO -- no go

Quote:
Originally Posted by jellyroll22 View Post
I checked the charging receptacle and got 36.2. When I plug the power wise q e digital charger in, it flashes 6 red blinks, which according to the charger indicates a fault. When checking the 2 large posts on the solenoid I get the same 36.2 reading but no clicks no matter what I try. In checking the batteries individually I get 6.2 for each except one which I get 5.1. So, two questions I guess. Could one battery being that far off of the others cause me these problems? #2 why no solenoid click like it's working? Ok, 3 I guess. If the charger is seeing 36.2 volts, why doesn't it come on?
Your solenoid is not clicking because it is not energizing. The voltage you are seeing on both big solenoid terminals is normal if it has a resistor across them. See if you have voltage on the small white wire coming off the charger receptacle with the charger unplugged. Next see if you have + voltage on either small terminal (the coil) on solenoid when you try to go.

One step at a time..

Don't know why charger is not coming on. (defective charger, battery problem connection etc) Borrow another charger from neighbor to test.

Your batteries are low because the charger is not coming on. You got the voltage (36.2) to turn it on when connected.

Lets get the solenoid to click first.

You can't guess too much about why a cart wont run without making some more voltage measurements.

Murphy's law will be right there with you if you do.
\
When you get voltage on the coil then we will turn attention to the other side of the coil if it doesn't energize.
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Old 05-30-2014, 08:56 PM   #5
jellyroll22
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Default Re: 07 PDS EZGO -- no go

Quote:
Originally Posted by radioman View Post
Your solenoid is not clicking because it is not energizing. The voltage you are seeing on both big solenoid terminals is normal if it has a resistor across them. See if you have voltage on the small white wire coming off the charger receptacle with the charger unplugged. Next see if you have + voltage on either small terminal (the coil) on solenoid when you try to go.

One step at a time..

Don't know why charger is not coming on. (defective charger, battery problem connection etc) Borrow another charger from neighbor to test.

Your batteries are low because the charger is not coming on. You got the voltage (36.2) to turn it on when connected.

Lets get the solenoid to click first.

You can't guess too much about why a cart wont run without making some more voltage measurements.

Murphy's law will be right there with you if you do.
\
When you get voltage on the coil then we will turn attention to the other side of the coil if it doesn't energize.
Checked charger receptacle. I have large white wire, large black wire, and small red wire with white trace (reed switch?). I have full pack voltage on red wire with white tracer.

Checked small terminals on solenoid. On the one furthest from the battery pack I have full pack voltage. Doesn't change with go pedal position. On the one closest to the battery pack I have 34.8 with key on, in 'run'. Same conditions with go pedal pressed to floor, it drops to 33.8. With all of these readings I am using negative post of last battery in line for black probe of DVM. Is this correct to do?

Just for grins I took out the weak battery and stuck a known good battery out of my cart in there, no change. Charger fails to turn on and flashes the same fault indicator. Doesn't appear to have made any difference.

And I appreciate the help. Thank you.
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Old 05-31-2014, 09:24 AM   #6
JohnnieB
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Default Re: 07 PDS EZGO -- no go

The six red flashes means the Powerwise QE is ready for "Mount Trashmore"
Replace it with one of these: http://www.cartsunlimited.net/48v_Battery_Charger.html

Connecting reverse polarity to the PDS controller probably killed it.
With charger unplugged from cart.
Run/Tow in Run
Key = ON
F/R in "F"
Pedal pushed
You should have B+ on all the pins with wires highlighted in red aon attached schematic and the solenoid should click.
If not, replace controller with a DCX400 like the Package#808 shown here (or larger) : http://www.cartsunlimited.net/Custom_Options.html
Attached Images
File Type: jpg tmp_0830120932382852519.jpg (259.4 KB, 0 views)
File Type: jpg Wiring Diagram - PDS - Solenoid activation traced.jpg (69.7 KB, 0 views)
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Old 06-02-2014, 02:16 PM   #7
jellyroll22
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Default Re: 07 PDS EZGO -- no go

I have B+ on all of the highlighted red wires on the schematic but still no solenoid click or propulsion. Do you still suspect controller?

Charger problem was fixed with a different charger, and wires going to the correct locations.

Again, thanks for the help.
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Old 06-02-2014, 05:49 PM   #8
JohnnieB
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Default Re: 07 PDS EZGO -- no go

Quote:
Originally Posted by jellyroll22 View Post
I have B+ on all of the highlighted red wires on the schematic but still no solenoid click or propulsion. Do you still suspect controller?

Charger problem was fixed with a different charger, and wires going to the correct locations.

Again, thanks for the help.
If you've got B+ on all the highlighted wire and solenoid does not click, the controller is most likely bad. (In rare instances, there can be a bad connection between the plug and the pins on the controller, so re-seat all the plugs, just to be sure)
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Old 07-01-2014, 09:03 PM   #9
jellyroll22
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Default Re: 07 PDS EZGO -- no go

Update and new questions.

charger and controller went to a local guy, former mechanic at a cart shop. So I now have a better charger, Mt trashmore for the fancy digital one.

Now into the controller. He said he took it apart and replaced all of the diodes /capacitors etc that were popped. I believe he knows what he is doing, but I guess you never know.

I put it all back together, doubled checked wiring schematics to make sure it was all right, doubled checked it again, then finally flipped to run and gave her a go.

Solenoid now clicks, but it acts funny and doesn't 'go'. What it does is with key on, in run, in forward, and pedal pressed the solenoid clicks as soon as the micro opens in the pedal box then the solenoid clicks again. It's like it closes and makes the connection, but only for a second. If I press pedal all the way down it does nothing but when the pedal comes back up the solenoid clicks closed then open again. No tire movement.

I read the ITS diagnostic thread here
http://www.buggiesgonewild.com/elect...onfused-2.html
And here is what I get. 14.2 volts as soon as I touch black probe to battery - with red probe on white wire in pedal box. Upon pressing the pedal it drops to 13.6 at full pedal press. Doesn't seem right compared to the other post. I have 37.2 total pack voltage.

Do I have a ITS problem ( which could have happened when it was all wired wrong) or do I still have a controller problem? The guy who worked on the controller says he has rebuilt hundreds of PDS controllers.
Oh, and thanks for the help.
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Old 07-02-2014, 07:35 AM   #10
JohnnieB
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Default Re: 07 PDS EZGO -- no go

Quote:
Originally Posted by jellyroll22 View Post
Update and new questions.

charger and controller went to a local guy, former mechanic at a cart shop. So I now have a better charger, Mt trashmore for the fancy digital one.

Now into the controller. He said he took it apart and replaced all of the diodes /capacitors etc that were popped. I believe he knows what he is doing, but I guess you never know.

I put it all back together, doubled checked wiring schematics to make sure it was all right, doubled checked it again, then finally flipped to run and gave her a go.

Solenoid now clicks, but it acts funny and doesn't 'go'. What it does is with key on, in run, in forward, and pedal pressed the solenoid clicks as soon as the micro opens in the pedal box then the solenoid clicks again. It's like it closes and makes the connection, but only for a second. If I press pedal all the way down it does nothing but when the pedal comes back up the solenoid clicks closed then open again. No tire movement.

I read the ITS diagnostic thread here
http://www.buggiesgonewild.com/elect...onfused-2.html
And here is what I get. 14.2 volts as soon as I touch black probe to battery - with red probe on white wire in pedal box. Upon pressing the pedal it drops to 13.6 at full pedal press. Doesn't seem right compared to the other post. I have 37.2 total pack voltage.

Do I have a ITS problem ( which could have happened when it was all wired wrong) or do I still have a controller problem? The guy who worked on the controller says he has rebuilt hundreds of PDS controllers.
Oh, and thanks for the help.
First, you need to get the solenoid to click and stay clicked while the pedal is down.
After that is done, we can then start troubleshooting the cart not moving.

The solenoid not staying activated could be a controller issue, or it could be a control wiring issue.

Lift the rear tires off the ground and put on jackstands so the half ton cart does take off unexpectedly and run over someone or something.

Have someone push the pedal down far enough to make the solenoid click and hold it there while you measure the voltages.
If all the wires highlighted in red on the schematic I attached to my Post#6 have pack voltage on them, the solenoid should stay energized.

If any of them looses voltage, the solenoid will drop out. Find and fix that circuit.

If the voltages are all there and the solenoid drops out, the controller is bad.

------------
Also, put controller into diagnostic mode. It might give an error code.
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