EZGO PDS Troubleshooting

[Hedger]

2004 pds, everything stock and bought without batteries. Cover was off of controller so controller is already suspect. Put in and charged new batteries and voltage is not a problem. I get nothing when i push the pedal. Fault code is 2-1. Solenoid resistor is getting real hot. Am I right to assume bad controller?

[JohnnieB]

Error 2-1 is low battery voltage. (As measured between the controller's B- and B+ terminals)

Precharge resistor getting hot when pedal is pushed indicates bad solenoid.

[Hedger]

Thanks for jumping in JohnnieB. Was waiting for you or Scotty. I removed the resistor and get pack voltage on battery side and both small posts of solenoid but nothing on the other big post. When I pull the 10 pin and measure voltage i get pack on 4,5 and 10, nothing on anything else. I have pack voltage coming off the reed switch. I ordered a solenoid.

[JohnnieB]

Solenoid probably isn't bad. The solenoid coil driver in the controller isn't putting B- on the blue wire.

Attached is a PDS schematic showing all the wires that have to have B+ on them to get solenoid to close.

Also attached a drawing showing the B+ path through the controller to the solenoid and one showing Pin-1 highlighted on all jacks.

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I'm shutting down for the night.

[Hedger]

So probably just the controller?

[JohnnieB]

Can't be sure what it is without troubleshooting the system.

However, based on the symptoms, one of the first things I'd check is the voltage on J4 Pin-1 when the pedal is pushed.

[Hedger]

I have nothing on j4-1

I have 15.1 on j4-4

I’m pulling the plug and going into the controller to measure, right?

[JohnnieB]

Originally Posted by Hedger

I have nothing on j4-1

I have 15.1 on j4-4

I’m pulling the plug and going into the controller to measure, right?

No.

Everything has to be plugged in.

Stick test probe into backside of plugged in plug.

[biphase]

PDS Bench Test

[Hedger]

Geez, that makes a difference. I get pack voltage when I press pedal on j4-1