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Old 12-01-2015, 02:53 PM   #1
lsudevildog
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Default Upgraded XCT400PDS and cart are lifeless

Hello,
I have a 2005 EZGO TXT. It was previously all stock, 36v system. In a dumba$$ move, I had the batteries disconnected to hook up connectors for an LED light harness and I managed to swap the polarity when I reconnected the battery cables to the controller. When I turned the key on, forward, and depressed the foot pedal, the cart did not move and I heard some clicking/popping behind me. I moved the F/R switch to reverse, and the buzzer sounded very weak and was getting weaker. Cart didn't move in reverse either. I moved the F/R switch to neutral, key off, then discovered the error of my ways. I couldn't get the controller to enter into the diagnostic mode and it appeared lifeless. Well, I was planning on upgrading the controller and batteries anyway, so I bought 7 new T-105's to bump up to 42v, and the XCT400PDS with SW180 solenoid and cables from ScottyB, along with a new 42v charger. So, that's the history, now to current events...
I got the new controller mounted, the F1 & F2 cables converted from spade connections to ring connections and the yellow and blue solenoid wires switched from ring to spade connections, the batteries installed, and all the new cables connected, including the A1 and A2 swapped out. I finalized the battery pack to controller connection, waited a minute, then flipped the Row/Tow switch to Run. Dashing my high hopes, the cart is still lifeless. The best I can tell, the new controller is lifeless. The status light doesn't come on or blink at all. In running diagnostics with a DVM, the new pack (uncharged) reference voltage is 43.4v. Voltage at the pack side of the large solenoid post is 43.4v. With the Run/Tow switch in Tow, I have no voltage on the controller side of the solenoid, but in Run I have 42.9v. That tells me that the Run/Tow switch is working. There is no voltage on either side of the key switch or the F/R switch. The controller isn't sending any power to them. I checked the continuity of the switches using the 10 pin and they behaved normally, meaning no continuity with the key/switch off, good tone with the key on and with the F/R switch in the correct position. That leads me to believe those switches are working. Checked the continuity of the foot pedal switch, and I get good continuity as soon as the pedal is depressed. Controller B+ to M- shows 0.00v. Doesn't matter if the key is on or off, F or R, pedal depressed or not, 0.00v. Controller B- to M- shows 42.9v unvarying with pedal movement, key switch, or F/R switch. I don't have a reed switch at the charging receptacle.
At this point, I could use some help trying to figure out what is wrong. I strongly suspect that something else is wrong from when I reversed the battery wires with the old controller and it's not the new controller. Any help would be much appreciated. Thanks
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Old 12-01-2015, 02:58 PM   #2
scottyb
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Default Re: Upgraded XCT400PDS and cart are lifeless

Sounds like a case of no power to the keyswitch or pedal box micro switch. Likely damage from the earlier mishap
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Old 12-01-2015, 03:08 PM   #3
cgtech
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Default Re: Upgraded XCT400PDS and cart are lifeless

A good possibility of fried reed switch.
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Old 12-01-2015, 03:12 PM   #4
scottyb
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Default Re: Upgraded XCT400PDS and cart are lifeless

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Originally Posted by cgtech View Post
A good possibility of fried reed switch.
05 was the change year so early 05 yes.... reed switch but, late 05 may be battery terminal fuse. Surprised the pedal box micro switch tests good, maybe retest that.
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Old 12-01-2015, 03:20 PM   #5
lsudevildog
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Default Re: Upgraded XCT400PDS and cart are lifeless

I don't have a reed switch in my cart.
Using the DVM, there is no voltage at the key switch. The continuity checks out thru the wire side of the 10 pin connector, thru the switch, and back to the 10 pin connector. Checking for voltage at the controller side of the 10 pin connector, I get nothing. It should be pushing pack voltage out correct? And wouldn't the status light on the controller be on either way?
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Old 12-01-2015, 03:42 PM   #6
lsudevildog
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Default Re: Upgraded XCT400PDS and cart are lifeless

The white insulation around one of the terminals looks to have gotten hot sometime in the past, but that is not a new thing and it charges fine.
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Old 12-01-2015, 04:31 PM   #7
lsudevildog
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Default Re: Upgraded XCT400PDS and cart are lifeless

The check the continuity of the foot pedal switch, I unplugged the 4 pin connector, C4 on the XCT PDS wire diagram, inserted one probe in pin1, green, and the other probe in pin 2, red. With the pedal up, there is no continuity. As soon as the pedal is depressed and you hear the switch click, the continuity meter buzzer squeals. With the meter is VDC and the negative probe on the Batt pack -, would you expect to see voltage at the controller side of C4 pins?
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Old 12-01-2015, 06:23 PM   #8
scottyb
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Default Re: Upgraded XCT400PDS and cart are lifeless

The cart will not run until the small red wire shown in the charge receptacle brings 36v+ to the key switch which allows 36v + to pass to the pedal switch which allows 36v+ to the solenoid small yellow wire and energizes the solenoid.

Check that out and let us know what you find.
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Old 12-01-2015, 07:26 PM   #9
lsudevildog
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Default Re: Upgraded XCT400PDS and cart are lifeless

That small red wire in the charge receptacle runs to under the passenger seat, then via a spade connection becomes the red/white wire that is pin4 in the 10 pin C4 connection. There is good continuity between the start of the red wire in the charge receptacle and pin4 going into the controller.
I don't see how that small red wire brings 36v+ to the key switch. The key switch is between pin8 and pin9 on the 10 pin connection. With the Run/Tow in run, there is no voltage at the key switch.
Even with a microswitch inop somewhere, wouldn't the controller status light come on? It is acting like it is lifeless.
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Old 12-01-2015, 07:42 PM   #10
scottyb
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Default Re: Upgraded XCT400PDS and cart are lifeless

Quote:
Originally Posted by lsudevildog View Post
That small red wire in the charge receptacle runs to under the passenger seat, then via a spade connection becomes the red/white wire that is pin4 in the 10 pin C4 connection. There is good continuity between the start of the red wire in the charge receptacle and pin4 going into the controller.
I don't see how that small red wire brings 36v+ to the key switch. The key switch is between pin8 and pin9 on the 10 pin connection. With the Run/Tow in run, there is no voltage at the key switch.
Even with a microswitch inop somewhere, wouldn't the controller status light come on? It is acting like it is lifeless.
Are you certain the C4 is fully engaged and the clip is clipped. Somebody had it in backwards and the clip did not line up - that did run when C4 was flipped around ?
I suppose it is possible the control is faulty - but that would be rare. Which pins have + power with R/T switch in run?
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