2004 PDS reverses 2 ft. then quits

[Randy102771]

2004 EZGO PDS cart will back up 2ft. sometimes 10 ft. then acts as if you took foot off gas. Reverse buzzer still sounds. Flip to forward then reverse does same thing for a few more feet. Runs like a charm going forward.
This is my neighbor's cart that he just bought today so we haven't done anything to it except to take the cover off and have a look at controller looking for loose wires. Everything appeared fine. Does not have chip in it. Tamper seal still intact.
Any ideas as to what we should check first?

[JohnnieB]

Be sure to put Run/Tow switch into Tow before disconnecting or reconnecting any wires. Also, put in Tow to push or tow cart.

What is the battery pack voltage? (Always start with a fully charged battery pack when troubleshooting)
What is battery pack voltage when misbehaving?
Does the solenoid clink when misbehaving?


Since direction control is done by the controller and the cart runs forward normally, and the battery voltage is good, and the solenoid clicks when pedal is pushed, and the beeper sounds continuously when in reverse, the controller is very likely to be bad.

[Randy102771]

Update: We replaced the controller and it made no difference. The cart will back up a few inches then stop as if you let off gas. Runs like a champ going forward. The pack voltage is fully charged. This problem occurs at all times regardless of state of charge. The audible back up alarm stays on even after it stops moving so I assume the F/R switch is OK. I am not sure as to whether the solenoid clicks or not. Only one solenoid for forward and reverse right? How do you check it? What else could cause this?

[JohnnieB]

Try reversing the F1 & F2 leads at the controller.

If the cart now goes forward with F/R switch in R, but won't go backward with F/R in F, check for a mechanical problem.
You should be able to push cart backward or forward by hand with about the same amount of effort.
(Flip Run/tow switch to Tow is walkaway safety kicks in.)

If cart now won't go forward in R, but will go backwards in F, Return F1 & F2 back to their original spots, pull the resistor of the solenoid's main terminals and reattach the high current cables without it.
Lift rear wheels off ground so the cart doesn't run over you.
Measure between B- and A1 on controller with DVM
Should measure battery pack voltage when the pedal is slightly pushed (Just far enough to close throttle microswitch) and reduce to zero when pedal is pushed to floor.
What do you get when cart misbehaves?