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Old 10-10-2012, 09:10 PM   #1
Ploki
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Default 2004 ezgo surging and beeping

hi have a 36v ezgo with new batteries and leads.It has started surging and when i come to a halt it beeps and applies the brake.it is worse when i have a passenger in the car or when i climb a hill.upon getting advice from an auto electrician who did a did a short test i replaced the controller and the problem persists.its a 2004 pds.
he said when he held a meter on the controller that 36v was going in and only 18v was coming out.any advice on what course i should take
cheers
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Old 10-11-2012, 10:58 AM   #2
JohnnieB
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Default Re: 2004 ezgo surging and beeping

Welcome to BGW!

What is the battery pack voltage? (Fully charged will be 38.2V, or maybe a bit higher since you said they were new batteries)

When the beeper beeps, is there a pattern to it or is it a just series of equally spaced beeps?

Try running cart in diagnostic mode and it might tell you what it thinks is wrong.
The text at bottom of attached label tells you how to put into Diag. mode and list some of the beep codes.
Attached Images
File Type: jpg PDS Label on Controller Cover.JPG (142.9 KB, 0 views)
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Old 10-11-2012, 02:50 PM   #3
Ploki
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Default Re: 2004 ezgo surging and beeping

where is the run tow maintainence switch? is this the switch on the cover of the controller,solenoid box?
the beep depends on the speed of the cart as it slows.if i come to a halt on a slight downhill it will beep several times as the brake engages automatically but if i come to a halt on the flat it will beep just once.
batteries are at 38.3v
thks for interest
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Old 10-12-2012, 05:08 AM   #4
JohnnieB
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Default Re: 2004 ezgo surging and beeping

Yes, it is the switch on the controller/solenoid cover.
Always put it in the Tow position when connecting or disconnecting anything electrical. Otherwise, you might destroy the controller.

By "surging", do you mean that the cart speeds up while the throttle is held steady?
If so, I suspect you have a controller that is starting to fail.

On the other hand, if by "surging" you mean the cart is slowing down (or seems to be loosing power) while throttle is held steady, it might be an intermittent connection in one of the 5 switch circuits (7 sets of contacts) that must be closed for cart to run, or the ITS (Inductive Throttle System) circuit, or the motor speed sensor.

If the surging is loosing power, I'd check for loose or dirty connections at the switches and at the controller. Unplug the connectors, give them a squirt of spray contact cleaner and plug in while still damp.
(Run/Tow must be in Tow while doing this!)

--------------
You can download the Owner, Parts and Service manuals from this post in the Stickies at the top of this forum.
http://www.buggiesgonewild.com/elect...g-manuals.html
They are the three .pdf files.

Here is a schematic for a PDS cart.
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File Type: jpg Wiring Diagram - PDS.JPG (64.6 KB, 0 views)
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Old 10-13-2012, 06:33 AM   #5
yurtle
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Default Re: 2004 ezgo surging and beeping

Quote:
Originally Posted by JohnnieB View Post
You can download the Owner, Parts and Service manuals from this post in the Stickies at the top of this forum.
http://www.buggiesgonewild.com/elect...g-manuals.html
They are the three .pdf files.
We need a Smilie that says this. Or maybe we should just add it to our sigs.
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Old 10-13-2012, 11:09 AM   #6
kgsc
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Default Re: 2004 ezgo surging and beeping

May want to check the speed sensor as well. May have a bad wire or connection.
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Old 10-14-2012, 02:23 PM   #7
Ploki
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Default Re: 2004 ezgo surging and beeping

Have sprayed and checked all the connectors.it's a loss of power situation rather than surging.have opened up the ITS looks ok? how do I test that and the speed sensor?
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Old 10-14-2012, 02:26 PM   #8
Ploki
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Default Re: 2004 ezgo surging and beeping

Have sprayed all the connections.it's a power loss problem rather than surging.
I have opened up the I T S and it looks fine.how do I test this and the speed sensor?
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Old 10-14-2012, 06:05 PM   #9
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Default Re: 2004 ezgo surging and beeping

One way to test it is to have the cart in forward and release the brake without hitting the gas pedal and let it roll, it should start beeping and apply the electric brake. If it does nothing I would suspect the sensor.
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Old 10-15-2012, 05:41 AM   #10
yurtle
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Default Re: 2004 ezgo surging and beeping

There's a MOLEX connector near the FNR, that has the throttle ITS and its microswitch. Mine needed cleaning.
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