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Old 11-22-2012, 08:33 AM   #1
SBG
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Default 06 PDS stopping cart

I bought my 06 Ezgo almost 5 years ago and haven't had any problems until 3 months ago. When driving along the alarm sounds and it feels like the motor is being electronically braked. As the cart is stopping I push on the brake and it feels like the motor is released. This may happen 4 or 5 times in one trip, or it may not happen for a week.
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Old 11-22-2012, 10:28 AM   #2
scottyb
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Default Re: 06 PDS stopping cart

What is the sequence or code it is beeping? Is this happening on a Fresh charge ? Are the batteries 5 years old?
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Old 11-22-2012, 10:35 AM   #3
JohnnieB
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Default Re: 06 PDS stopping cart

Welcome to BGW!

The problem could be caused by a lot of things.
Low battery voltage
Thermal cut-back
Intermittent speed sensor
Loose connection at about two dozen places
Controller going bad

!!!!! Be sure to place Run/Tow switch into TOW before disconnecting or reconnecting any electrical wiring!!!!!


What is battery pack voltage about 12 hours after charger shuts off?
What is battery pack voltage when cart misbehaves?
Does solenoid stay engaged while cart is misbehaving?
When alarming, does alarm sound continuously or does it beep?
If it beeps, are the beeps rhythmic or is it a beep-code?

The PDS is more or less a "Fly-by-Wire" system. but fortunately there are all that many wires to troubleshoot.
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Old 11-22-2012, 11:45 AM   #4
SBG
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Default Re: 06 PDS stopping cart

WOW! I had no idea it could be so many different things, looks like I have a lot of research to do, Thanks. I think.
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Old 11-22-2012, 12:15 PM   #5
JohnnieB
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Default Re: 06 PDS stopping cart

It isn't all that bad.

Check if the controller is getting hot.
Check the high current cables for heat.
Check the battery voltage
Pull the plugs on the controller (Run/Toe in TOW), spray contacts in both plugs and jacks with contact cleaner and plug/unplug a couple times while still damp.

If that doesn't find or fix problem, we will proceed from there.
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Old 11-22-2012, 12:28 PM   #6
SBG
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Default Re: 06 PDS stopping cart

In response to scotty b, #1- I disconnected the beeper,but as I remember it was short fast beeps, and would stop once the cart came to a complet stop. Then I could press on the accelerator and everything would be fine. And it might happen again in 5 mins or 2 mins or not for 2 day or 1 week. #2- Yes, it can happen as soon as I unplug and leave the house, or after I have been out for hours. I have not been able to find a pattern. #3- Yes, but I still get at least 18 miles on a charge and haven't noticed any real fall off.
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Old 11-22-2012, 12:34 PM   #7
SBG
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Default Re: 06 PDS stopping cart

Jonnieb, How long of a run (time wise) to check if controller is hot.
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Old 11-22-2012, 01:09 PM   #8
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Default Re: 06 PDS stopping cart

Quote:
Originally Posted by SBG View Post
Jonnieb, How long of a run (time wise) to check if controller is hot.
Whenever the cart is misbehaving. Take the cover off and then just fasten it on loosely with the upper two bolts.

---------
However, what you are describing, short beeps and regen braking until cart stops, sounds more like one of the pins on the controller is loosing B+ momentarily.

While driving along, shift the F/R rocker switch to neutral. That should give you the same symptoms.

The tricky part is that there are 13 pins on the controller that have to have B+ (Battery pack voltage) on them for the cart to move and loosing B+ on just about any of them will also produce the same results.

Here is a schematic for your cart.
There likely suspects are the following 5 switches and the wires connecting and them to the controller, and their connections.
Starting from the left going clockwise.
1. Reed switch
2. Direction Selector (F/R) switch
3. Pedal switch
4. Run/Tow switch
5. Keyswitch

Intermittent problems are fun to troubleshoot, aren't they?
Attached Images
File Type: jpg Wiring Diagram - PDS.JPG (64.6 KB, 0 views)
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