2002 pds contoller

[birdleg1981]

I have a cart that was droppep off for me to repair. The client put batteries in and now the cart will not run. Im gna wing this the best I can, cause I had all my readings on a pad.but left them at work. This is a 02 pds 36volt cart. Pack voltage is at 37.85 volts. the cart is dead wont move nor the solenoid clicks. I have power thru the key switch, cart in on position fwd and in run mode. I check the go pedal switches and they are working as should. reed switch has been bypassed already. Now I check voltage at controller on the plug from go pedal I get 37 on green and 37 on red..the.other 2 I have.nothing regardless of pedal position. Now I check for power on small.terminals wiyh.ground lead on last negative battery I get power. I also have power on.big.solenoid posts, but yet no click. So I put.in a new spare solenoid and same.thing.no.click. from what I read.the solenoid is on different.circuit then controller. don't understand why no click. Can the controller be toast and not allow solenoid to engage somehow? I got no clue. Sorry.its so long. Im laying in bed on my cell trying to.explain the.best way possible.. Thanks randall..

[birdleg1981]

Also the fault code doesn't do anything. I get no beeps at all. The buzzer is hooked up also.

[rib33024]

If you haven't already, go to the STICKY's at the top of the Electric EZGO forum and download the Owner, the Service and the Parts manuals for you cart.
They are the 3 ".pdf" files here:Basic Ezgo electric golf cart wiring and manuals

Attached is the schematic for a PDS cart.
As you see the solenoid is activated by the controller and for that to happen 5 switches must all be closed.
1. Reed Switch. B+ to J1-P4.
2. Key Switch. Shorts J1-P8 to J1-P9
3. F/R Switch. Shorts J1-P1 to either J1-P2 (R) or J1-P3 (F)
4. Run/Tow Switch. Shorts J3-P1 to J3-P2 and J3-P3 to J3-P4
5. Pedal Switch. Shorts J4-P1 to J4-P2

You say you've got B+ on small wire coming out of charger receptacle, so it should be present at J1-P4 there unless Red wire is broken or disconnected, but I would check for its presence with a voltmeter just to be sure.

I would also Check for B+ on J1-P5. That comes from the battery side main terminal of the solenoid.

Switches #2 through #5 above can all be checked with an Ohmmeter by unplugging the plugs at the controller and measuring across the specified pins while toggling the respective switches.

Be sure to put Run/Tow switch in Tow before unplugging any plugs.

Let us know what you find.

Originally Posted by JohnnieB

[birdleg1981]

Thanks. Ill.get on that in the morning. My phone wouldn't let me download them. Ill try to print them.out tomar. Once.again.thanks

[JohnnieB]

Originally Posted by birdleg1981

Also the fault code doesn't do anything. I get no beeps at all. The buzzer is hooked up also.

No beeps at all from beeper?

1. Bad/disconnected beeper
2. Bad controller
3. B+ and B- cables from battery pack reversed at solenoid and controller.

May not be the problem with this cart, but reversed main cables on the battery pack was the problem found with the cart in the thread Rib linked to.

Probably wouldn't hurt to verify owner put them on right when he changed batteries.


Also, hopefully owner put Run/Tow switch in Tow before changing out batteries, else the controller might be toast.

The tricky part about solenoid activation with a PDS controller is that it is a two step process.
First, B+ has to be applied to via J1 Pin-7. (Reed switch = closed, Run/Tow = Run, Key = ON, F/R = F or R and J1 Pin-5 = B+)
Then, when pedal microswitch closes, B- is applied to other side of solenoid coil via J1 Pin-7.

[birdleg1981]

The cart is actually wired up.properly.. I have the feeling.they.didn't switch.to tow as well. Headed to shop now, gna check where I do and do not have power according to the schematic

[birdleg1981]

k here is what i did so far. cart is wired as it should be. this is for RIB..reed switch checks good as well as key switch f/r switch, run/tow and pedal switch all work as should. i have voltage at j1-p4 and also j1-p5... johnnieB beeper is connected and b+ b- cables hooked up correct to solenoid. now when i check b+ to j1-p7 i get voltage. with negative lead on end battery i get voltage at small posts on solenoid and also at large posts. still nothing moves. when i checked all voltages negative lead was always on main negative battery.

[birdleg1981]

i just did the troubleshooting test from the pdf files. it is taking to replace controller. i checked it twice just to be sure. is there a certain type of controller i should be looking at if thats the issue?

[JohnnieB]

Sure sounds like controller is bad.

Type controller depends on what cart owner wants.
If he/she wants to stick with a PDS controller FSIP (Site Sponsor) has a re-manufactured 350A 1206MX for $221 and change, less for dealers.
(If & when I blow my controller - this is what I will probably get )
http://fsip.workxpress.com/page/link...4715d721&wxm=1
They also have new 350A PDS controllers, but it is call for price.

If customer wants to go aftermarket for more speed/torque, Scottyb (Site Sponsor) has some package deals.
http://www.cartsunlimited.net/Custom_Options.html

[birdleg1981]

Cool..thank.yall for the help!! Once I get controller.installed ill chime back in.