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Old 08-07-2012, 10:12 PM   #1
joe53
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Default another 2002 PDS problem

First off I want to say I have read alot in this forum and thank you all for the information.
My problem is with a 2002 EZGO 36v PDS model. I just bought it and had to put new batteries in it. It ran when I got it home. I pulled it into the garage and hooked up the charger.Charger seems to work also. I was going to ride it again later and nothing. No clicking at the solenoid (that I can hear) and no movement. I checked the codes and got a 1-2 beep.
This said something about the ITS. I checked it by voltage and had the black meter lead hooked up to the - on the battery and tested the white wire on the ITS with switch in RUN position, key on and in forward. I got 12.4 volts consistant with pedal up or down.
Does this sound like the problem? Thanks for any input I can get.

Also I disconnected the two wires and checked the leads on the ITS for continuity and nothing.
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Old 08-07-2012, 10:51 PM   #2
scottyb
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Default Re: another 2002 PDS problem

Welcome to bgw, Test with black lead at B- and red lead at the white wire, what do you get with the peddle up? and down?
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Old 08-08-2012, 07:40 AM   #3
joe53
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Default Re: another 2002 PDS problem

When I tested it that way it was 12.4 with no changing as the pedal is moved. Another question is why 12.4?

Thanks.
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Old 08-08-2012, 07:53 AM   #4
scottyb
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Default Re: another 2002 PDS problem

One last question, is this a stock Curtis controller or aftermarket Alltrax?
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Old 08-08-2012, 08:00 AM   #5
joe53
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Default Re: another 2002 PDS problem

I think it is stock but I didn't see any name on it. Looking at it and the other types it appears stock. I will have to look again when I get home.
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Old 08-08-2012, 08:04 AM   #6
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Default Re: another 2002 PDS problem

Try one more time to get a good test following the Ezgo manual. Let me know what you get. It is very rare an ITS unit goes bad but it can happen. The controller may have failed
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File Type: jpg Ezgo ITS testing.jpg (281.3 KB, 0 views)
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Old 08-08-2012, 08:11 AM   #7
joe53
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Default Re: another 2002 PDS problem

Thats another problem. In the testing it says you can hear the solenoid click. My solenoid is not clicking when I push the pedal down or a least I can't hear it clicking. I hear the clicking from the switch at the pedal. I tested it and it is working.
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Old 08-08-2012, 08:23 AM   #8
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Default Re: another 2002 PDS problem

That is a problem, use the solenoid activation circuit diagram to trace the problem out then when the solenoid clicks, if the cart still does not go, test the ITS.
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Old 08-08-2012, 08:28 AM   #9
JohnnieB
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Default Re: another 2002 PDS problem

I'm seeing two sets of symptoms here.
1. Beeps code (1-2) is a throttle fault. Could be ITS or controller.
2. Solenoid not clicking (Clunking). Could be controller or microswitch in throttle box, or something else in solenoid activation circuit.

Most likely suspect is the controller, but could be two separate problems.

Flip Run/Tow to Tow and disconnect J4 at controller.
Flip back to run, key on and F selected.
You should measure 15V +/- 1V at J4 Pin-4 on the controller. This is where white wire connects when plug is attached to controller.
If you still get 12.6V, the controller is probably bad.
If voltage is within the 14 to 16 volt range, the ITS is bad, or maybe the wiring to/from it.

Note, if the 15V regulated power supply is defective (Logic supply), the solenoid activation circuit might not work.

Voltage would probably be different with an aftermarket controller, so check their ITS specs if you have one.

Last edited by JohnnieB; 08-08-2012 at 08:31 AM.. Reason: added info
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Old 08-08-2012, 08:41 AM   #10
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Default Re: another 2002 PDS problem

Wow - Just noticed the wire color in the Text of the service manual doesn't match the wire colors on the schematic.

White wire is ITS output to controller in text, but voltage source on the schematic. The troubleshooting tree indicates J4 Pin-3 is the ITS output and J4 Pin-4 is the voltage source, so I guess it is whatever color wire go to those pins on the cart.

Sorry if I caused any confusion.
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