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Electric EZGO Electric EZ GO Marathon, Medalist, TXT and RXV. |
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08-17-2018, 03:11 PM | #1 |
Not Yet Wild
Join Date: May 2018
Posts: 9
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EZGO Solenoid Compatibility
I have a 2007 EZGO PDS 36V that has been shutting down periodically. I changed out the stock controller with the Alltrax XCT48500-PDS and the MZJ-400A Solenoid and cable upgrade. It did not fix the problem. Cart was still shutting down. I have gone through all of the tests I could find on this site and a couple of others and everything seems, no shorts, etc. Now the controller is giving me a green/light flashing signal indicating a short circuit/output fault.
For now, I have reinstalled the stock controller with the MZJ-400A solenoid and it seem to be running OK upon jacks. Until I get the new controller issue resolved, will it hurt the old stock controller or motor to use the 400 solenoid? I am still trying to run down the original problem, but don't want to damage something else during the process. Thanks, |
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08-17-2018, 04:08 PM | #2 |
Techno-Nerd
Join Date: Jun 2011
Location: West Virginia
Posts: 19,654
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Re: EZGO Solenoid Compatibility
Stock PDS controller ought to be OK with the MZJ-400.
Check the F1/F2 cables for worn insulation where they are routed around the frame. |
08-17-2018, 04:28 PM | #3 |
Happy Carting
Join Date: Dec 2007
Location: Southern California
Posts: 73,406
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Re: EZGO Solenoid Compatibility
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08-17-2018, 07:18 PM | #4 |
Not Yet Wild
Join Date: May 2018
Posts: 9
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Re: EZGO Solenoid Compatibility
Thanks, I’ll revisit that. I did build myself new ones (F1 & F2) before the controller failed. I’ll try putting the old ones back on and see if it helps. The error message on the controller just began all of a sudden. I did not order new 10g ones when I replaced upgraded the other cables.
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08-18-2018, 10:02 AM | #5 |
Techno-Nerd
Join Date: Jun 2011
Location: West Virginia
Posts: 19,654
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Re: EZGO Solenoid Compatibility
Is the any precursor to the failures? IE: going up a long hill, or driving at top speed for a long distance, or carrying more weight than usual.
Describe the cart more. Rear seat? Lifted? How tall are the tires? Stock (12.44:1) differential gears? Stock PDS motor? (If so, was XCT48500 turned down to 400A?) ---------- When cart shuts down, does it beep rapidly and regen braking come on or does it quietly coast to a standstill? --------- If it was my cart with this problem, I'd reinstall the XCT, connect a laptop to it and record datalogs of every trip until I captured a failure on one. The XCT armature and filed outputs are short circuit protected and you say you got a Short Circuit/Output Fault alarm, but if there was a significant short in either the armature or field output circuits, the stock PDS controller would no longer be working since it lacks short circuit protection. If you can capture the failure on a datalog, zip the .csv file and post it here. (You cannot attach a .csv file to a post, but you can attach a .zip file) |
08-18-2018, 10:12 AM | #6 |
Not Yet Wild
Join Date: May 2018
Posts: 9
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Re: EZGO Solenoid Compatibility
Thanks for the heads up about the F1/F2 cables. I inspected them once more and found a worn spot on the F2. I'm pretty sure that's been part of the ongoing problem all along. I will replace them shortly.
I now trying to determine the problem I am having with the Alltrax controller. I put it back on my cart this morning and am still getting the single green/red flashing light indicating a short circuit/output fault. The stock controller with the DC solenoid seems to work fine. Any thoughts on what might cause this? It was working earlier in the week when I was trying to isolated the shut down problem. Are there diagnostics to test the controller? Thanks, |
08-18-2018, 10:44 AM | #7 |
Not Yet Wild
Join Date: May 2018
Posts: 9
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Re: EZGO Solenoid Compatibility
JohnnieB, The cart is still pretty much stock other than I did add a rear seat. It's not lifted and has the 8" tires. Not sure about the differential. I haven't changed anything on it. When the cart shuts down it starts beeping rapidly, I don't notice anything with the braking. It just rolls to a standstill.
I suspect the worn F2 cable is causing the problem, now that I found it this morning. I also wonder if the White-Rodgers solenoid was getting too hot, since the outside temperature seem to affect how often it was shutting down. Often, it would shut down after hitting a bump which points back to the cable, also. I am currently running the stock motor, and was in the process of upgrading it once if determined what was causing the shutdown. I bought the controller and solenoid together for a 36v cart. I assumed it was paired, but not sure. |
08-18-2018, 10:45 AM | #8 |
Techno-Nerd
Join Date: Jun 2011
Location: West Virginia
Posts: 19,654
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Re: EZGO Solenoid Compatibility
Short circuit/ output fault error. Check the motor out with an Ohmmeter.
A1 to A2 ought to measure between 0.3Ω to 1.0Ω F1 to F2 ought to measure between 1.0Ω to 2.0Ω A1 to F1 ought to measure OPEN F1 to Case ought to measure greater than 5MΩ If the XCT output was greater than 400A, the stock PDS motor might have gotten cooked. ---------------- XCT Diagnostics: Connect a laptop to it via a USB cable. The "Toolkit" program that is used to program it, has a monitor page that shows errors, voltages, amps, which contacts are closed, controller temperature, throttle position, ETC. Also, you can store the monitored parameters in a file on the laptop, which can later be viewed and analyzed in a spreadsheet. There are forty monitored parameters, plus date and time. Attached is the monitor screen and the data logging controls are circled. |
08-18-2018, 11:04 AM | #9 |
Not Yet Wild
Join Date: May 2018
Posts: 9
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Re: EZGO Solenoid Compatibility
Thanks, I will check it out. I had my laptop connected to the controller last week when it was up and running and was trying to make sense of it. I will hook it up again and see what it says.
I have read on this site that there's potential to burn up the stock motor, so I have been babying it. It is still running as of now with the Curtis controller. Are these measurements with the cables detached? Also, you have A1 to A2 shown twice. Is one a typo? I'm still pretty new at all of this. A1 to A2 ought to measure between 0.3Ω to 1.0Ω F1 to F2 ought to measure between 0.3Ω to 1.0Ω A1 to F1 ought to measure OPEN A1 to A2 ought to measure greater than 5MΩ |
08-18-2018, 11:07 AM | #10 | |
Techno-Nerd
Join Date: Jun 2011
Location: West Virginia
Posts: 19,654
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Re: EZGO Solenoid Compatibility
Quote:
A rear seat increases weight and takes more torque to run the cart. The rapid beeping sound tells me you have a intermittent F/R switch or Keyswitch, or wiring to those switches. At least those are the most likely suspects. If you try to change directions on the F/R or shut off the key while cart is moving, the controller (both stock and XCT) does an emergency shutdown and yells at you. The push-on connectors in your cart's wiring have been collecting corrosion for over 10 years and the wires crimped into the push-on connectors have been wiggling for over 10 years, so poor connections and frayed wires are most definitely possible. Move the F/R switch to neutral while traveling and you should duplicate the failure mode. The XCT48500 and MJZ400 are a match made in Heaven. The both will operate at 36V, 42V and 48V, and will max out the performance of most motors that will fit your cart. ---------- If you do swap motors in the future. be sure the get the correct Field Map for the new motor. |
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alltrax 500, pds controller, stopped running |
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