2001 PDS Motor Stall

Brown32 · 10-11-2021, 04:22 PM

Gents,
I know there are several threads on here and I have went thru them multiple times. Here is where I am. 36v all stock, freedom mode. I have had an issue for two years plus with intermittent "Run away mode and regen braking" when going down hill normally when WOT. This issue comes and goes, some days bad, some days not at all. When using around the yard it doesn't happen.

Now this has evolved and I am having a motor stall to the point the cart can't be driven. I have it torn apart and I was convinced that after reading another lengthy post on here that it was for certain the ITS. However I went thru the trouble shooting tree and when I perform the steps for checking voltage starting at controller and then to the motor with full throttle press I have momentary voltage that is required, the motors spins, then it goes to zero, motor stops and the it gives me the 4-2 motor stall code beep. No voltage says to replace motor.

Is this the motor or a different issue? Thanks for any help.

JohnnieB · 10-11-2021, 05:08 PM

A stock PDS controller in freedom mode limits the motor to about 4400RPM on level ground and tries to limit the motor to not much more than that going downhill WOT by using regen braking. IIRC when I was running a stock PDS controller back in 2011, I got about 19MPH on level ground and maxed out at about 21MPH going downhill WOT.

If the cart was intermittently not applying regen braking when going downhill at more than about 20MPH or so, then there are issues with the speed sensor or the controller.

I'm not sure what criteria triggers the 4-2 error, but going to 0RPM (no pulses from speed sensor) while the motor is drawing several amps might do it.

Make sure the screw holding the magnet disk in place on the motor shaft is tight and make sure sensor is properly positioned. (There are two snap rings and both have to be in their groove to properly position the sensor)

----------
If you have an automotive type DMM with a tachometer function, you can read the motor's rpm between pins 1 & 2 on J5. Set to 8cyl and it'll read the motor RPM directly.

Brown32 · 10-11-2021, 05:23 PM

Thanks for the quick reply. The cart does apply braking when it happens downhill. Beeping and heavy heavy braking.

I just pulled the rear drums off to make sure the rear-end wasn't binding. It will sometimes turn the motor instantly and run forever but most times it clicks the solenoid tries to run or either runs for a few seconds and shuts off.

Solenoid sometimes clicks multiple times as well. on off on off type of deal which made me think it was the solenoid contacts. Part of me still believes that the solenoid is dropping out.

I will check to see if this snap on meter can read rpm and I will also check the speed sensor.

Brown32 · 10-12-2021, 09:37 AM

I do not have an option for Hz on my blue point or my fluke meter. I have further more done the following.

Speed sensor is in place with the snap ring.

Cart will now only run for just a few seconds and I haven't gotten it to run for an extended time for a while now, no load, it is on jack stands.

I am no longer getting a motor stall tone.

Solenoid pulls in, motor runs for about 1.5 to 3 seconds and shuts off. If I leave the pedal depressed the solenoid will go back open and it just sits there until I release the pedal, once the pedal switch cycles again it will repeat the process.

I have also tested the ITS. White wire has 15v standing, it drops to 14.9 - 14.6 as soon as it runs for a second. Once it stops running it goes back to the 15v. From everything that I have read this is too high, correct?

JohnnieB · 10-12-2021, 10:50 AM

Sounds like it is time to replace the controller.

Replace it with an Alltrax XCT48400-PDS user programmable controller.

Brown32 · 10-12-2021, 11:31 AM

Thank you for the help. The last time it ran under a load for a ways it went into creep or I guess limp mode and the controller and motor were extremely hot.

Where is the best place to purchase the alltrax controller?

JohnnieB · 10-12-2021, 11:34 AM

This is where I got mine: https://www.cartsunlimited.net/alltrax-xct-sepex--.html

Brown32 · 10-12-2021, 11:54 AM

Thank you.

Brown32 · 10-14-2021, 01:58 PM

Solenoid solved the problem. We shall see how long it last. Thanks for the help Johnny

10-11-2021, 04:22 PM	#1
Brown32 Not Yet Wild Join Date: May 2020 Posts: 14	2001 PDS Motor Stall Gents, I know there are several threads on here and I have went thru them multiple times. Here is where I am. 36v all stock, freedom mode. I have had an issue for two years plus with intermittent "Run away mode and regen braking" when going down hill normally when WOT. This issue comes and goes, some days bad, some days not at all. When using around the yard it doesn't happen. Now this has evolved and I am having a motor stall to the point the cart can't be driven. I have it torn apart and I was convinced that after reading another lengthy post on here that it was for certain the ITS. However I went thru the trouble shooting tree and when I perform the steps for checking voltage starting at controller and then to the motor with full throttle press I have momentary voltage that is required, the motors spins, then it goes to zero, motor stops and the it gives me the 4-2 motor stall code beep. No voltage says to replace motor. Is this the motor or a different issue? Thanks for any help.
Brown32 Not Yet Wild Join Date: May 2020 Posts: 14

10-11-2021, 05:08 PM	#2
JohnnieB Techno-Nerd Join Date: Jun 2011 Location: West Virginia Posts: 19,654	Re: 2001 PDS Motor Stall A stock PDS controller in freedom mode limits the motor to about 4400RPM on level ground and tries to limit the motor to not much more than that going downhill WOT by using regen braking. IIRC when I was running a stock PDS controller back in 2011, I got about 19MPH on level ground and maxed out at about 21MPH going downhill WOT. If the cart was intermittently not applying regen braking when going downhill at more than about 20MPH or so, then there are issues with the speed sensor or the controller. I'm not sure what criteria triggers the 4-2 error, but going to 0RPM (no pulses from speed sensor) while the motor is drawing several amps might do it. Make sure the screw holding the magnet disk in place on the motor shaft is tight and make sure sensor is properly positioned. (There are two snap rings and both have to be in their groove to properly position the sensor) ---------- If you have an automotive type DMM with a tachometer function, you can read the motor's rpm between pins 1 & 2 on J5. Set to 8cyl and it'll read the motor RPM directly.

10-11-2021, 05:23 PM	#3
Brown32 Not Yet Wild Join Date: May 2020 Posts: 14	Re: 2001 PDS Motor Stall Thanks for the quick reply. The cart does apply braking when it happens downhill. Beeping and heavy heavy braking. I just pulled the rear drums off to make sure the rear-end wasn't binding. It will sometimes turn the motor instantly and run forever but most times it clicks the solenoid tries to run or either runs for a few seconds and shuts off. Solenoid sometimes clicks multiple times as well. on off on off type of deal which made me think it was the solenoid contacts. Part of me still believes that the solenoid is dropping out. I will check to see if this snap on meter can read rpm and I will also check the speed sensor.
Brown32 Not Yet Wild Join Date: May 2020 Posts: 14

10-12-2021, 09:37 AM	#4
Brown32 Not Yet Wild Join Date: May 2020 Posts: 14	Re: 2001 PDS Motor Stall I do not have an option for Hz on my blue point or my fluke meter. I have further more done the following. Speed sensor is in place with the snap ring. Cart will now only run for just a few seconds and I haven't gotten it to run for an extended time for a while now, no load, it is on jack stands. I am no longer getting a motor stall tone. Solenoid pulls in, motor runs for about 1.5 to 3 seconds and shuts off. If I leave the pedal depressed the solenoid will go back open and it just sits there until I release the pedal, once the pedal switch cycles again it will repeat the process. I have also tested the ITS. White wire has 15v standing, it drops to 14.9 - 14.6 as soon as it runs for a second. Once it stops running it goes back to the 15v. From everything that I have read this is too high, correct?
Brown32 Not Yet Wild Join Date: May 2020 Posts: 14

10-12-2021, 10:50 AM	#5
JohnnieB Techno-Nerd Join Date: Jun 2011 Location: West Virginia Posts: 19,654	Re: 2001 PDS Motor Stall Sounds like it is time to replace the controller. Replace it with an Alltrax XCT48400-PDS user programmable controller.

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10-12-2021, 11:31 AM	#6
Brown32 Not Yet Wild Join Date: May 2020 Posts: 14	Re: 2001 PDS Motor Stall Thank you for the help. The last time it ran under a load for a ways it went into creep or I guess limp mode and the controller and motor were extremely hot. Where is the best place to purchase the alltrax controller?
Brown32 Not Yet Wild Join Date: May 2020 Posts: 14

10-12-2021, 11:34 AM	#7
JohnnieB Techno-Nerd Join Date: Jun 2011 Location: West Virginia Posts: 19,654	Re: 2001 PDS Motor Stall This is where I got mine: https://www.cartsunlimited.net/alltrax-xct-sepex--.html

10-12-2021, 11:54 AM	#8
Brown32 Not Yet Wild Join Date: May 2020 Posts: 14	Re: 2001 PDS Motor Stall Thank you.
Brown32 Not Yet Wild Join Date: May 2020 Posts: 14

10-14-2021, 01:58 PM	#9
Brown32 Not Yet Wild Join Date: May 2020 Posts: 14	Re: 2001 PDS Motor Stall Solenoid solved the problem. We shall see how long it last. Thanks for the help Johnny
Brown32 Not Yet Wild Join Date: May 2020 Posts: 14

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