EZGO PDS - New ALLTRAX XCT48500 and 400a solenoid install. no light - newbie

[JohnnieB]

Voltage on C1 Pins with:
A. Battery charger disconnected
B. Run/Tow in RUN
C. F/R in F
D. Key ON
E. Pedal not pushed.

Pins: (note 36V mean full battery pack voltage, which is 38.@V when fully charged)
1 = 36V
2 = 0V (36V if R is selected on F/R)
3 = 36V (0V if R is selected on F/R)
4 = 36V
5 = 36V
6 = 36V (Solenoid coil feed through -- 0V when solenoid is activated)
7 = 36V
8 = 36V
9 = 36V
10 = 36V (Beeper feed through -- 0V when beeper is sounding)


Pin-5 should have 36V on it 100% of the time the battery pack is connected.
Pin-4 should have 36V on it when battery pack is connected and battery charger is disconnected.

[JohnnieB]

Verify C1 and C3 plugged in correctly.

I managed to plug one of them in when offset by one row when installing my XCT and I beat my head against the wall for a while before I found my oops.

[greenguru]

Thanks for the information. I will recheck that the connectors are plugged in correctly. Now I know what voltages to expect on each pin I can be persistent with the meter until I get what i expect. I may have not measured the correct voltages due to C1's convenient location.

I spoke with the Alltrax tech yesterday and he confirmed the run/tow switch is bad.

I have a new run/tow switch with wires and connector on the way. Should have it tomorrow.

I will let you all know what I find.

Shawn

[JohnnieB]

The new Run/ow switch will most likely fix the voltage readings.

[greenguru]

The good news:

The new Tow/Run switch has arrived. I installed it and the Alltrax controller now lights up green when I turn the key. When i flip the reverse switch the buzzer sounds. The meter on the dash now lights up with a full charge.

The bad news:

I step on the throttle, the solenoid clicks, and there is no movement forward or reverse.

Motor?

Shawn

[JohnnieB]

Solenoid clicks, but cart doesn't move. That narrows it down to the high current cables, field cables, throttle, solenoid contacts as well as the motor.

Easier tests first.
1. When you turn key on, XCT's LED ought to blink green four times and then go to steady green.
2. If so, push pedal to floor and LED should turn to a steady yellow (amber), or it might be a blinking yellow. Steady Yellow means 100% throttle, blinking yellow mean 100% throttle with current limiting.

3. With Key on and direction selected, connect DVM between XCT's B- and M- terminals. Push pedal just far enough to make solenoid click and you should read full battery pack voltage (38.2V if fully charged).
4. If you do get pack voltage, slowly press pedal to floor and the voltage should smoothly decrease to 0V or thereabouts.

5. Find the black and the white wires in C4 (Pins 3 & 4) and connect your DVM to them. Ought to measure 10V with pedal up and 6V with pedal on floor.

--------------
That's all for now. Stop testing at first failure and post.

[greenguru]

JohnnyB ,

Test results.

1. Passed. Green/4 Green flashes/Steady Green.

2. Failed = No Amber of any kind - Just stays green.

Shawn

[scottyb]

Test the ITS throttle signal... http://www.buggiesgonewild.com/elect...e-testing.html

[greenguru]

ScottyB,

My C4 White wire measures 8. When the pedal is pressed to floor 6.3V.

C4 Black and White measure 7.3V.


Pack is at 37.2

Extra note:

When you press pedal in FWD 1 Green Flash and 1 Red. No movement

When you press in Reverse 1 green Flash and 6 Red. The cart moves slightly before the Alltrax starts flashing.

Thanks

Shawn

[greenguru]

Motor test time? Thoughts on alltrax lights?