New Controller and Solenoid Now The Cart Wont Work

BBIGGS88

So I have an Ezgo Pds currently a 36 volt. I am working on converting the cart to a 48 volt. I bought the controller and heavy duty solenoid that should run on 36 pr 48 volt. Alltrax 500 amp controller and heavy duty solenoid both from Scotty B. When I turn the key on with the F/R switch in neutral I get four green lights and then a solid green light indicating everything is good. When I pish the F/R switch to forward or reverse the solenoid clicks and then I get a green followed by a red light. This flashes over and over green red pause green red pause and every couple of flashes the solenoid clicks again. Whats everybody's opinion on how to troubleshoot. Before we start I have a few notes I would like to make that may or may not help the only thing that changed from the picture is I removed the green resistor

1. I changed out the micro switch while doing this upgrade.

2. When connecting the controller for the first time I hooked up the 3a diode on the small posts and the green resistor on the larger posts after it gave me this code I added the 6 a diode on the large posts with the resistor. After talking with scotty b I learned I needed the 6 a diode and no resistor.

3. The cart ran before I changed the controller and solenoid.

Where do I start all your help is appreciated

BGW

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BBBHC

The beauty of the Alltrax controllers, is that you can hook them up to a computer for trouble shooting. They utilize a printer cable to do this. I would start there. You'll want to do this for the future anyway to dial in different settings for maximum performance and/or to dial it down in different settings for different circumstances.

scottyb

The controller is giving a fault code 1 green 1 red. In the back of the operator manual is a list of fault codes. This one is a short circuit on the output side. Likely you could have the not uncommon Ezgo bare cable syndrome.

The Alltrax has already paid for itself. Where other controllers die from this or any short circuit created by motor failure the XCT simply protects itself and notifies the operator of the fault.

If the wires are not bare, and no motor connection is incorrect or shorted out, then the motor may be bad.


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BBIGGS88

Thanks for the input Im new to this so I appreciate the help. What is bare cable syndrome? I tried to search it but couldnt find anything I am running 2 ga cables on the cart. Scotty b thanks for the patience and good customer service I already emailed you like 3 times prior to this.

handtools

The cables that run from the controller to the motor run along the frame and often rub the insulation off and short to the frame.

BBIGGS88

So if the cables are brand new could it just be the motor is toast?

BBIGGS88

If Im understanding what you guys are saying is it is on the output side of the controller. So it would be A1, A2, F1, F2 or the motor. A1 and A2 are brand new 2 ga cables. F1 and F2 are original but I traced them and can not see any places where wire is exposed. Could it be the F1 or F2 wire is worn enough to short it but not worn all the way through? The only other thing would be the motor correct?

handtools

Have you tested the motor? Here is a thread with details on the procedure.

http://www.buggiesgonewild.com/elect...pex+motor+test