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Old 10-26-2019, 03:38 PM   #1
Thrillercart
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Default Alltrax controller not lighting up

I have an EZGO 1996 TXT 36v. I upgraded the controller and selenoid from Scotty a year ago to the XCT400/200 combo. The cart was quickly losing power after riding for a bit this summer. So we havent been using it much since. I just tried to take it out and the cart wont move. The light on the ALLTRAX isnt coming on at all. I don't hear the selenoid "click" like it used to when turned on. Batteries are fully charged, my key seems to have continuity when turned on, i have 38v in bottom of selenoid and 38v into the 2 top ports of the Alltrax. Again there is no light on the Alltrax and no "clicking" on the selenoid. Any ideas? wont move at all, and the cart seemed to not run very long late this summer the last several times i drove it. Thanks
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Old 10-26-2019, 05:19 PM   #2
JohnnieB
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Default Re: Alltrax controller not lighting up

Quote:
Originally Posted by Thrillercart View Post
I have an EZGO 1996 TXT 36v. I upgraded the controller and selenoid from Scotty a year ago to the XCT400/200 combo. The cart was quickly losing power after riding for a bit this summer. So we havent been using it much since. I just tried to take it out and the cart wont move. The light on the ALLTRAX isnt coming on at all. I don't hear the selenoid "click" like it used to when turned on. Batteries are fully charged, my key seems to have continuity when turned on, i have 38v in bottom of selenoid and 38v into the 2 top ports of the Alltrax. Again there is no light on the Alltrax and no "clicking" on the selenoid. Any ideas? wont move at all, and the cart seemed to not run very long late this summer the last several times i drove it. Thanks
If the controller isn't being turned on, the solenoid isn't going to energize.

What is the voltage of the solenoid's coil terminal with the three wires on it?
Ought to be battery pack voltage (38.2V when fully charged), if not find where it goes missing.

To get the XCT48400-DCS (1996 is a DCS drive) to power up there needs to be battery pack voltage on Pins 6, 9 & 10 and the B- cable connected. (Or a computer connected via the USB port)

Once the XCT is turning on, we can troubleshoot why the solenoid isn't clicking if it still isn't, and then we can try to figure out why it is losing power and not running as long. (Probably battery issues)
Attached Images
File Type: jpg XCT in DCS.jpg (246.4 KB, 0 views)
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Old 10-27-2019, 06:59 PM   #3
Thrillercart
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Default Re: Alltrax controller not lighting up

Thanks so much!! good info. I'll be checking all this tomorrow.. Let you know what i find
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Old 10-30-2019, 02:52 PM   #4
Thrillercart
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Default Re: Alltrax controller not lighting up

JonnieB, With the key on or off, I'm getting B pack voltage on #10. I'm getting 2v on #9 with key on or off. I'm getting 2V on #6 with key on and 0v with key off. The disconnect switch will kill all power to #10 if turned off, but will hold B pack voltage with key on or off with switch on... Thanks for any additional help you can provide. With why i'm not getting battery pack voltage to 6 and 9, and why 10 has pack voltage w key off or on.. Thanks for any more help!
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Old 10-30-2019, 03:36 PM   #5
JohnnieB
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Default Re: Alltrax controller not lighting up

Voltage source for both pins 6 and 9 is the same, the reed switch in the charge receptacle.

Check voltage on smallest of the three wires coming out of the backside of the charge receptacle.
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Old 10-30-2019, 05:07 PM   #6
Thrillercart
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Default Re: Alltrax controller not lighting up

I did. It is battery pack voltage if i check it to positive end of last battery in pack. FYI the battery pack is at 34.8v (36v cart). If i plug charger in the voltage jumps to 38-39v while charging immediately. If i unplug it, the voltage goes back down below 36v. These batteries are 2018 and watered above cells as they should. The weird thing is the light on controller wont come on still. Gosh. is something pulling on the batteries constantly when sitting or something?
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Old 10-30-2019, 05:53 PM   #7
scottyb
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Default Re: Alltrax controller not lighting up

Batteries self discharge. They should be above 36 volts. Plug them in and let the charger cycle
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Old 10-30-2019, 06:09 PM   #8
Sergio
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Default Re: Alltrax controller not lighting up

Thrillercart, I am not sure if You checked the wire that JohnnieB mentioned, but that wire brings the power to the red/white wire on your Tow/Run switch, do You have power there?
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Old 10-30-2019, 06:27 PM   #9
JohnnieB
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Default Re: Alltrax controller not lighting up

Quote:
Originally Posted by Thrillercart View Post
1. I did. It is battery pack voltage if i check it to positive end of last battery in pack.

2. FYI the battery pack is at 34.8v (36v cart). If i plug charger in the voltage jumps to 38-39v while charging immediately. If i unplug it, the voltage goes back down below 36v. These batteries are 2018 and watered above cells as they should.

3. The weird thing is the light on controller wont come on still.

4. Gosh. is something pulling on the batteries constantly when sitting or something?
1. The attached schematic with voltage path to Pin-9 highlighted is shows a stock DCS controller, but the Alltrax is the same. You say you have B+ on the wire from the Reed switch, so the Run/Tow switch, the wires to or from it or the connector is the problem.

2. & 4. Your batteries are dead. (15% SoC) Charge them immediately.
As mentioned, lead-acid self discharge at about 1% SoC per day.

Also, the controller constantly draws a few milli-amps.

3. The controller will not power up until B+ is present on Pin-6, 9 & 10.
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Old 10-31-2019, 10:06 AM   #10
Thrillercart
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Default Re: Alltrax controller not lighting up

Thanks guys, Will check this afternoon. its got to be something simple somewhere.
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