Panic attack - Need help - new controller, solenoid and cables

cmalberto

What an adventure. Just finished wiring new cables(50.5v) end to end - all good hear.

Wired new controller; Altrax DCX 500 w/CC IQ board to convert to CC wiring harness. Solenoid(HD) w/diode and resistor. Made sure diode was the right direction. Wired per directions and Scotty's diagram - they were the same but very helpful on the cables.

First of all when I turn tow switch back one and then the key, I get on 23 volts on the dash meter. - I have 50.5v or so from the battery. I have traced voltage to the Solenoid - both sides 50.5. I have 50.5 at the controller(B-) and then 50.5 back to A2 on the motor.

On the controller, I have solenoid to B+ plus From B+, I have cable going to to A2; from M-1 1 cable to A1; F1(10g wire) goes F1 and F2(10g) goes to F2.

Controller flashes 7 times then solid green; This is good the best I can tell.

Oh yea - the reverse buzzer goes on when I switch into reverse and the Solenoid clicks when I press the pedal - Forward or reverse. Obviously, it just doesn't go anywhere or I wouldn't be in a state of panic right now.

I am at a complete lost and frustrated needless to say. I have no idea what to try or test next. I need some ideas. The wife is going to kill me needless to say.

2009 CC 48v Exel

Thanks in advance.

BGW

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pete959

check ur wire connections at the controller board

cmalberto

I did - second time now. Pretty simple actually with the board that plugs on the pins. You can seem them pushed down properly as well.

And to make matters worse, it won't charge - I used Scotty's pin through the OBC to bridge the negative wire from the batter to the pin and then to B- on the controller - I also had 2 other ground wires coming out of the OBC that was connected to the old controller along with the negative wire. I replaced these to the B- as well. Not sure this has any thing to do with it but I read alot about bad OBCs that won't let the charge take place.

The charger does click - just doesn't shove any amperage across.

I did check from B- to B+ and had full pack voltage so I know I have a good negative across the pin.

cmalberto

OK guys - charging is fine. Suffice it to say I am tired. It helps to plug the charger in. So let's take the not charging symptom off the table.

I will await your great ideas - that's all for today though. Dinner, shower and chill time.

Will try again tomorrow.

cmalberto

Some other things that I have tried and checked yesterday...Reset OBC per Alltrax troubleshooting docs. Verified voltage on the solenoid(small terminals with DIODE) was really correct. Pack voltage with the correct polarity, both forward and reverse.

No trouble codes on the controller. Solid GREEN LED after 7 green flashes(confirms the club car IQ); Stays green when in FWD or REV with the pedal pressed.

Nothing, nada, zilch.

Later yesterday afternoon, I remember the solenoid and controller and re-installed the original equipment. The cart runs fine.

I don't know what to think. Some sort of incompatibility to the Exel system with the IQ controller board on the Controller? At a complete loss. I have emailed Alltrax support and waiting to hear back from them.

Thoughts, comments...crying towel?

scottyb

In a similar case this summer the little adapter board was defective. That's rare but it did happen, so I guess it could happen again. This can be determined with some Alltrax tech supported testing. Put the control and solenoid in the cart for testing.

cmalberto

On phone with Alltrax tech support a couple of times today. They had me check the ohms/resistance of the MCOR coming into the wiring harness with both the PCB chip/harnesss to the controller and without. There comment on my results is that the numbers were reasonable enough to at least move the cart. He did comment but was confirm with another person there that the Alltrax controllers may not work with the 2009 or 2010 Excel carts based on Club Car's better idea - I picked up on the sarcasm. Be that as it may he is supposed to have called back - still waiting :) - I will call them back in the morning to see what they say.

Speedchaser

It will not work on Excel.

However, Tahoe Dawg has mentioned numerous time that if you get an IQ wiring harness that it will work.

cmalberto

Hopefully TahoeDawg may chime in on this thread.

I vaguely remember seeing something about someone getting an IQ wiring harness.

So is the IQ wiring harness a complete replacement or just a converter from EXCEL to IQ? Meaning, will have I have to pull the existing harness out and replace with the IQ variety. Is this plug and play or other wiring changes needed?

Hopefully you guys will chime in and give some advice.

I will try to go back and find the thread I saw - maybe reach out to some folks individually and invite them to contribute to this thread and to continue the content of this thread.

Thanks as always for your comments; now and future.

Sasser

I was in the exact same situation. Tahoe Dawg guided me through the process and it will work. Part cost around $100 from a dealer. I did mine this past weekend per Tahoe's instruction and installed an Alltrax 500 amp controller and cables. My upgrade hasnt been flawless but I believe my problem is due to a faulty MCOR which I have ordered. The wiring harness Part No. is 103374901. It is plug an play and is fairly simple to replace. Just follow the schematic.