2008 Workhorse 48v PDS won't run

Duster · 07-18-2010, 11:03 AM

2008 48v PDS Workhorse - pulled it into the garage the other night running fine, now nothing works. Battery pack reads 53 volts, all cables look good. I had unhooked the reverse alarm, so I hooked it back up and even it doesn't work, so I can't even go into diagnotic mode. No clicking from the solenoid. Tested the reed switch by jumping the red wire to a positive battery terminal - nothing. Headlights and horn still work fine, charged it last night. Help!!!

Thanks,
Duster

rabbitreborn · 07-18-2010, 11:21 AM

What is the flash code on the controller giving you for a trouble code?

Duster · 07-20-2010, 06:41 PM

The factory wire harness under the cart which leads to the key and F/R switch had a broken 3-way splice in it. With the cart in reverse (on the jack stands), wiggling the harness would make the reverse alarm come on now and then. Cut off the harness covering and discovered the bad splice, and now it's fixed. Goes to show that most problems are related to bad wires/cables - even with a cart that is only 2 years old.

BTW - the flash code once the alarm worked was related to the pedal box, so I started there but eventually found the real problem.

Duster

rabbitreborn · 07-20-2010, 08:33 PM

Duster, you got EXTREMELY lucky.... When that cart first came out, that POS butt splice cost many golf courses thousands of dollars in replacement controllers..... luckily you caught yours before it fried that controller. When I worked for E-Z-GO, we found that faulty butt splice and told the factory about it.... they swore it was ok, until we sent them about 20 controllers that had blown because of that splice.... then they said they would re-locate the splice lmao....

LostHusker · 07-20-2010, 08:36 PM

Rabbit, the techs never know what they are talking about do they LOL

rabbitreborn · 07-20-2010, 08:53 PM

LMAO.... never...... I told John Garrison (he was CEO of E-Z-GO at the time I worked for them) once at a branch review meeting that if he ever wanted to truely fix the problems we had in the field, he would force the Engineers to spend 2 weeks a year in the field actually working on the carts they designed...... needless to say, it never happened.

gornoman · 07-20-2010, 08:56 PM

That's because the engineers are clearly smarter than the techs. Afterall, they have degrees from college......

scottyb · 07-20-2010, 09:26 PM

..well at least they are sitting at their desks in their chinos while we are lying on a concrete floor in our jumpsuits under a cart they F'ed up

rabbitreborn · 07-20-2010, 09:38 PM

Quote:

Originally Posted by gornoman

That's because the engineers are clearly smarter than the techs. Afterall, they have degrees from college......

lmao... I was offer a scholarship..... working to help keep the family afloat seemed more important to me then......

Quote:

Originally Posted by scottyb

..well at least they are sitting at their desks in their chinos while we are lying on a concrete floor in our jumpsuits under a cart they F'ed up

Amen to that!

Duster · 08-21-2013, 07:08 PM

Bumping this thread - same cart, 3 years later. Won't move, no solenoid clicking. It has the original 2008 trojan batteries (poorly maintained), 412 hours on cart. Can't get any diagnostic codes to beep out. Maybe just needs new batteries?

Battery #:
1: 6.38
2: 6.39
3: 6.40
4: 6.35
5: 6.33
6: 6.34
7: 6.29
8: 6.31

Total battery pack reading: 44.4

Batteries were very "dry", I added water and recharged before the above readings.

Should I just get a new set of batteries or troubleshoot further?

Thanks,
Duster

07-18-2010, 11:03 AM	#1
Duster Not Yet Wild Join Date: Jul 2010 Posts: 6	2008 Workhorse 48v PDS won't run 2008 48v PDS Workhorse - pulled it into the garage the other night running fine, now nothing works. Battery pack reads 53 volts, all cables look good. I had unhooked the reverse alarm, so I hooked it back up and even it doesn't work, so I can't even go into diagnotic mode. No clicking from the solenoid. Tested the reed switch by jumping the red wire to a positive battery terminal - nothing. Headlights and horn still work fine, charged it last night. Help!!! Thanks, Duster
Duster Not Yet Wild Join Date: Jul 2010 Posts: 6

07-18-2010, 11:21 AM	#2
rabbitreborn Gone Wild Join Date: Jun 2010 Location: Central Florida Posts: 2,757	Re: 2008 Workhorse 48v PDS won't run What is the flash code on the controller giving you for a trouble code?

07-20-2010, 06:41 PM	#3
Duster Not Yet Wild Join Date: Jul 2010 Posts: 6	Re: 2008 Workhorse 48v PDS won't run The factory wire harness under the cart which leads to the key and F/R switch had a broken 3-way splice in it. With the cart in reverse (on the jack stands), wiggling the harness would make the reverse alarm come on now and then. Cut off the harness covering and discovered the bad splice, and now it's fixed. Goes to show that most problems are related to bad wires/cables - even with a cart that is only 2 years old. BTW - the flash code once the alarm worked was related to the pedal box, so I started there but eventually found the real problem. Duster
Duster Not Yet Wild Join Date: Jul 2010 Posts: 6

07-20-2010, 08:33 PM	#4
rabbitreborn Gone Wild Join Date: Jun 2010 Location: Central Florida Posts: 2,757	Re: 2008 Workhorse 48v PDS won't run Duster, you got EXTREMELY lucky.... When that cart first came out, that POS butt splice cost many golf courses thousands of dollars in replacement controllers..... luckily you caught yours before it fried that controller. When I worked for E-Z-GO, we found that faulty butt splice and told the factory about it.... they swore it was ok, until we sent them about 20 controllers that had blown because of that splice.... then they said they would re-locate the splice lmao....

07-20-2010, 08:36 PM	#5
LostHusker Just one day at a time Join Date: Sep 2009 Location: South TX Posts: 8,650	Re: 2008 Workhorse 48v PDS won't run Rabbit, the techs never know what they are talking about do they LOL

Today
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07-20-2010, 08:53 PM	#6
rabbitreborn Gone Wild Join Date: Jun 2010 Location: Central Florida Posts: 2,757	Re: 2008 Workhorse 48v PDS won't run LMAO.... never...... I told John Garrison (he was CEO of E-Z-GO at the time I worked for them) once at a branch review meeting that if he ever wanted to truely fix the problems we had in the field, he would force the Engineers to spend 2 weeks a year in the field actually working on the carts they designed...... needless to say, it never happened.

07-20-2010, 08:56 PM	#7
gornoman Stay thirsty my friends! Join Date: Jan 2007 Location: Suburban Chicago Posts: 24,286	Re: 2008 Workhorse 48v PDS won't run That's because the engineers are clearly smarter than the techs. Afterall, they have degrees from college......

07-20-2010, 09:26 PM	#8
scottyb Happy Carting Join Date: Dec 2007 Location: Southern California Posts: 73,410	Re: 2008 Workhorse 48v PDS won't run ..well at least they are sitting at their desks in their chinos while we are lying on a concrete floor in our jumpsuits under a cart they F'ed up

08-21-2013, 07:08 PM	#10
Duster Not Yet Wild Join Date: Jul 2010 Posts: 6	Re: 2008 Workhorse 48v PDS won't run Bumping this thread - same cart, 3 years later. Won't move, no solenoid clicking. It has the original 2008 trojan batteries (poorly maintained), 412 hours on cart. Can't get any diagnostic codes to beep out. Maybe just needs new batteries? Battery #: 1: 6.38 2: 6.39 3: 6.40 4: 6.35 5: 6.33 6: 6.34 7: 6.29 8: 6.31 Total battery pack reading: 44.4 Batteries were very "dry", I added water and recharged before the above readings. Should I just get a new set of batteries or troubleshoot further? Thanks, Duster
Duster Not Yet Wild Join Date: Jul 2010 Posts: 6

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