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Old 02-03-2017, 02:44 PM   #1
pgroveguy
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Default EZGO PDS - No 6 pin connector, what white wire?

I am attempting to diagnose my power loss problem using stickys here and at Carts Unlimited. I'm pretty sure I have an '05 PDS.

I replaced solenoid after I got identical voltage readings on both +/- posts. No change. ( I still get identical voltage readings and fluctuating power)

Moving on to ITS diagnostics Carts Unlimited page says "With meter neg. probe on the B- terminal, use the positive lead to probe the white wire in the controller main molex connector.

Curtis OEM control signal range for :
Series & DCS carts should read 0.4 - 0.6 through 1.5 - 1.7 volts
PDS carts should read 1.0v - 2.7v (+/- 0.5v)"

I have no white wire in my 10 pin molex connector.

The diagnostic sticky here says,
"With the key switch ON - Forward direction selected - Push the Accelerator pedal just enough to activate the solenoid.
Install a "jumper wire" between the batteries BL+ post and the solenoid post with red wires attached.
AT THE SIX PIN CONNECTOR OF THE CONTROLLER
Place the (+) probe on the red wire terminal of the connector.
If battery voltage is not present, the red wire between the solenoid and the six pin connector is faulty.
Place the (+) probe on the black wire terminal of the connector.
The reading should be slightly above 14 volts but than 15 volts. If the voltage is not correct, the Throttle Sensor MAY be faulty."

Maybe I have something wired wrong. Why would I install a jumper from battery pack + post (my PDS does not have a left and right bank) if the cable is already direct connected to the solenoid post with the red wire? And I have no 6 pin connector.

What am I doing wrong?
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Old 02-03-2017, 04:55 PM   #2
scottyb
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Default Re: EZGO PDS - No 6 pin connector, what white wire?

Can you post a few pics of what you have ?
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Old 02-04-2017, 10:24 AM   #3
pgroveguy
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Default Re: EZGO PDS - No 6 pin connector, what white wire?

No tag in the glove box. I think the date code means it's a 2004.
Tow switch unplugged and removed.
Attached Images
File Type: jpg batteries.jpg (184.8 KB, 0 views)
File Type: jpg controller.jpg (187.3 KB, 0 views)
File Type: jpg txtpdsdatecode.jpg (166.9 KB, 0 views)
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Old 02-04-2017, 11:04 AM   #4
JohnnieB
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Default Re: EZGO PDS - No 6 pin connector, what white wire?

Looks like you have a 2004 PDS.

White wire is J4 Pin-4. J4 is second plug from bottom on left side of your picture #2.

However, for a PDS the ITS output is the black wire at J4 Pin-3.

Here is the schematic as well as the ITS checkout from the service manual
Attached Images
File Type: jpg Wiring Diagram - PDS.JPG (129.4 KB, 0 views)
File Type: jpg PDS ITS check-1.JPG (31.2 KB, 0 views)
File Type: jpg PDS ITS check-2.JPG (92.6 KB, 0 views)
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Old 02-09-2017, 08:24 AM   #5
pgroveguy
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Default Re: EZGO PDS - No 6 pin connector, what white wire?

TYVM JohnnieB.
The diagrams are excellent. I thought for certain I had a bad ITS because at step 43 the voltage would drop from 2.4+ and the motor would decelerate accordingly. But a new ITS later, the output from the ITS is good, but the fluctuating speed problem continues.

I'm trying to continue with controller output testing, I'm supposed to check at M-, but the PDS 36v diagram that looks the most like my cart doesn't show M- on the controller. I've got B+ B- A1 F1 F2

Where should I be testing?
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Old 02-09-2017, 09:23 AM   #6
JohnnieB
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Default Re: EZGO PDS - No 6 pin connector, what white wire?

M- (Motor negative) is labeled A1 (Armature - Stud-1) on a stock PDS controller.
If the test procedure you are using says M-, it might not be for a PDS cart.

Download the Service, the Parts and the Owner manuals here: http://www.buggiesgonewild.com/elect...g-manuals.html
They are the top three PDF files. The PDS troubleshooting tree starts on Page F-10.

Please describe what the cart is doing more concisely. Just saying the speed or power fluctuates leaves a lot of room open for interpretation and speculation.
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Old 02-11-2017, 08:18 AM   #7
pgroveguy
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Default Re: EZGO PDS - No 6 pin connector, what white wire?

The problem I am trying to diagnose is when I first depress the accelerator the cart accelerates normally, but then usually within 10 seconds the speed drops off to 25% or less. Wide open throttle achieves only a crawl. Sometimes the car will speed back to to normal for a few seconds before slowing back to a crawl.
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Old 02-11-2017, 09:04 AM   #8
scottyb
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Default Re: EZGO PDS - No 6 pin connector, what white wire?

If the ITS signal remains consistent the motor speed magnet or the magnet signal wires may have failed
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Old 02-11-2017, 09:57 AM   #9
BobBoyce
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Default Re: EZGO PDS - No 6 pin connector, what white wire?

Quote:
Originally Posted by pgroveguy View Post
The problem I am trying to diagnose is when I first depress the accelerator the cart accelerates normally, but then usually within 10 seconds the speed drops off to 25% or less. Wide open throttle achieves only a crawl. Sometimes the car will speed back to to normal for a few seconds before slowing back to a crawl.
What size tires/wheels are on your cart? I read through your posts and did not see this mentioned. Larger tires affect the effective rear end gear ratio.

It's sounding like you may be suffering from thermal cutback on the controller. Having too low of an effective gear ratio causes the motor to turn much slower at a given speed than the drive system was designed for. This overloads the motor and controller. Damage caused by overload will slowly add up until the controller and/or motor fail.

Bob
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Old 02-11-2017, 10:19 AM   #10
JohnnieB
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Default Re: EZGO PDS - No 6 pin connector, what white wire?

Put controller into diagnostic mode and listen for the beeped error codes.

The text at the bottom of the attached label tells you how to get into diagnostic mode.

At least three of the four reduced performance error conditions listed on label will give you reduced speed which can go away and then come back. Speed sensor issues and overheating being two of them. Low battery voltage being the third.
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File Type: jpg PDS Label on Controller Cover.JPG (142.9 KB, 0 views)
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