2004 PDS Alltrax XCT Install gone wrong

Mattk11

Posting here in hopes someone may know what i did wrong. I am getting 4 green LED flashes (EZGo ITS throttle), then pause, then 2 green LED flash and 3 red LED flashes (High throttle over range). My previous Curtis controller worked fine. There was no issues with the accelerator and everything was smooth. I just needed more torque because our golf course and neighborhood is hilly and we added a back seat.

2004 EZGo PDS, installed the Alltrax XCT PDS 400 amp controller and SW180 200 amp Solenoid. Took me a while to figure out the Solenoid because it was not the same layout as the one that was stock in the cart.

Here is how everything is wired - lower left is B- cable to the batter pack:


Closeup of the solenoid - Red wire is on the plus side with the cable from positive side of battery pack and cable to the B+ on the controller. There is a diode between the two screw posts with the strip on the positive side:


Last pic is close-up of B+ on controller:


I cannot figure it out. Anyone have any ideas? Thanks in advance

BGW

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Volt_Ampere

If it is complaining about throttle, that is where you need to look for a problem. Is the Alltrax programmed for the correct kind of throttle? Is the throttle cable hooked up correctly?

Mattk11

I'm not sure. I think it is hooked up correctly. I don't know how to trouble shoot it.

scottyb

The 4 green flash then solid green before the pedal is depressed indicates program for Ezgo PDS. Then you get the throttle error code 2/3 when you press the pedal, Make sure your C1 plug is in the correct orientation ( clip lines up as shown in the install diagram and it is fully inserted in the F1 receptacle.

JohnnieB

Also make sure J4 (C4 on controller) is properly oriented and fully seated.

Try clearing the throttle auto-cal. (See attached)

To check throttle on a XCT-PDS controller:

Measure between the Black and White wires on J4. (Push test leads into backside of connected molex plug)
Should read 10V with pedal up and 6V with pedal on floor.

Attached Images

Clear Throttle Auto-Cal.jpg (53.0 KB, 0 views)

JohnnieB

Took a closer look at third picture in Post#1. J4 is installed backwards.

Green wire ought to be closest to the center of controller and white wire ought to be closest to edge.

scottyb

Email revealed white throttle wire was connected to the personality plug.
So Hopefully this is fixed now?

Just a general note to others please zoomed in pictures like these are of little help to us as we are looking to see the big picture. (where wires go) We can zoom in if needed but we cannot see more than you are letting us see. Thank you

Mattk11

Thank you so much to Johnnie and Scotty. I did not see that the C4 plug was backwards. It seated with no problem when I was plugging everything together. Install instructions were difficult for me to follow not because they were wrong but because there weren't enough photos for me to trouble shoot myself. Thanks again!!!

JohnnieB

Glad to hear you got it going.

I also noticed your high current cables appear to be different gauge cables. They should all be 4Ga or thicker.

PingEye3

It appears to me in picture 2 of post #1 that there is no diode installed on the solenoid.