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Electric EZGO Electric EZ GO Marathon, Medalist, TXT and RXV.



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Unread 02-24-2019, 11:05 AM   #11
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Default Re: Lost going forward then reverse

@yurtle: PDS cart don't have the in-line connector, the gray cable from the pedal box is longer and connects directly to a 4-pin jack on controller (J4), so the in-line connector is not needed to facilitate assemble at factory.

Series drives have it and DCS drives have it, but IDK about the TXT48.
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Unread 02-24-2019, 11:09 AM   #12
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Default Re: Lost going forward then reverse

Good to know. Too bad, as that could have explained the symptoms.

Can regen cause the tires to lock up, screeching, then later run normally? If not, he may have had a mechanical and electrical/electronic problem at the same time. He did hit a bump, so maybe...
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Unread 02-24-2019, 11:35 AM   #13
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Default Re: Lost going forward then reverse

The stock PDS controller had a crash stop "feature" that applies max regen braking when one of the voltages needed for solenoid activation dropped out, and so did the DCX controllers I used to run as well as the XCT I'm currently running. Plus they may have Plug Braking, the purpose of which is to keep the motor from locking up when the direction is reversed while the motor is turning.

If there is a loose connection, a bump could have initiated a crash stop, but it clears as soon as cart stops, unless the bad connection still exists.

The issue of one direction working and the other not working, points towards the F/R rocker switch and wiring.
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Unread 03-01-2019, 05:23 PM   #14
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Default Re: Lost going forward then reverse

I’ve driven the cart about 5 miles thus far, stop and go, top speed, over speed bumps and other dips in the road.

I can definitely say the tires locking was a roll away crash stop kicking in. I have had zero issues going forward or in reverse. I have checked all connections.

Is it possible water could have been the culprit since it was driven in the rain?

Not sure where else to look? Thanks for your help
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Unread 03-01-2019, 05:50 PM   #15
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Default Re: Lost going forward then reverse

Just stay away from that evil bump in the road.

It sounds like it was a "bad connection" that was initiated by a bump, then later "fixed itself", which maybe could have been water. I'm not a PDS guy, but knowing what conditions trigger a "run away" cart may help you know where to look for a possible loose connector. I'd guess it would take a signal mismatch between the throttle switch and/or the ITS versus the signal from the motor speed sensor. In other words, the controller "sees" the cart "running away" without there being a key switch on and/or throttle being pushed. Again, just my guess. The inline connector I was referring to previously has to do with the throttle microswitch and the ITS. Both of those have been known to cause problems after getting water in the throttle box. If that's the case, I don't know why it took a bump to reveal itself, unless conditions were just right, water sloshing around?
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Unread 03-01-2019, 06:06 PM   #16
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Default Re: Lost going forward then reverse

If any of the switches or plugs got wet, there could have been some cross-talk between pins in the various plugs.

J1 Pin is pack voltage to F/R switch, Pin-2 is Reverse and Pin-3 is Forward, Pins 1 & 2 are next to each other and with enough cross-talk between them, the controller might think Reverse was being selected while moving forward and initiate a crash stop. That is speculation on my part, but you could ask Alltrax.

I know for sure that changing the F/R or turning off keyswitch while moving will stop the cart very quickly. When done at 25MPH, my tires will slide on dry pavement, but when done under 10MPH the Regen braking isn't strong enough to slide tires on dry pavement.
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Unread 03-02-2019, 08:10 AM   #17
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Default Re: Lost going forward then reverse

So I went back today to the same “ bump” that started this all.
After driving over it again I can tell you 100% it was a true crash stop engagement since I had a front passenger that was much heavier than me and a rear passenger side passenger as well that was also heavier than me. The cart was already passenger side heavy before we went over this particular bump with both drivers side wheels.

I haven’t been able to reproduce the symptoms all week but just when over a large street hill that’s been dug up and re-patches by the city multiple times and was able to loose throttle for about two seconds and then it engaged again.

After this happening it now definitely seems like a loose connection. Is there anything I should check near the gas pedal? I know there is that box on the underside of the cart that has the sensor? I have a basic multimeter. Or should my approach be to drive around looking at the throttle position with a laptop to see if it reads throttle position when it does happen because then it would cue to the controller output?
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Unread 03-02-2019, 08:45 AM   #18
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Default Re: Lost going forward then reverse

I'd remove the floor pad and look inside the throttle box. Could be a bad or corroded connector. Short of that, an intermittent throttle microswitch could be a possibility, as it is a mechanical device that's 12 years old, and cheap and easy to replace.

I don't remember hearing of intermittent problems with ITSs, but anything's possible.
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Unread 03-02-2019, 08:49 AM   #19
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Default Re: Lost going forward then reverse

Quote:
Originally Posted by Conradconrad View Post
So I went back today to the same ď bumpĒ that started this all.
After driving over it again I can tell you 100% it was a true crash stop engagement since I had a front passenger that was much heavier than me and a rear passenger side passenger as well that was also heavier than me. The cart was already passenger side heavy before we went over this particular bump with both drivers side wheels.

I havenít been able to reproduce the symptoms all week but just when over a large street hill thatís been dug up and re-patches by the city multiple times and was able to loose throttle for about two seconds and then it engaged again.

After this happening it now definitely seems like a loose connection. Is there anything I should check near the gas pedal? I know there is that box on the underside of the cart that has the sensor? I have a basic multimeter. Or should my approach be to drive around looking at the throttle position with a laptop to see if it reads throttle position when it does happen because then it would cue to the controller output?
You don't need to watch the laptop. Simply start datalogging and try to reproduce the event. It may log the throttle switch independent of the ITS. You'd have to be sure to not let off the throttle, in order to catch the event, then end the datalogging session, so you'll know where to look.
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Unread 03-06-2019, 06:58 AM   #20
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Default Re: Lost going forward then reverse

Opened up the throttle box and everything looks pretty much brand new, the previous owner must have replaced it prior to my purchase(I’ve had the cart since 2/2017). Nothing was corroded, loose or odd looking. Checked/traced the wiring from the box all the way to controller connection, no visual concerns.

I rechecked all connections on controller and did notice J8 on the controller, which goes to F2 on the motor, just loose enough that you could move the wire end lug up and down between the J8 terminal sides. Retightened it and the proceeded to check tension with a socket on the remainder of the bolts on the controller

Checked all battery connections, checked all motor connections, traced speed sensor wire to see if it may have rubbed against frame but it was perfect.

Took out the dash plate and checked connections on the F/R switch for issues or any visual corrosion, all good there.

Drove the cart around again for about 2 miles, no issues. Will try to find time to drive it on a bumpy section of road and see if I can get it to loose throttle input.
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