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Unread 11-03-2019, 05:38 PM   #1
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Default EZGO PDS - New ALLTRAX XCT48500 and 400a solenoid install. no light - newbie

The stock controller in my cart died a couple of weeks ago. I went through the EZGO diagnostics I found here, and determined controller was bad.

I upgraded the Controller and Solenoid on my EZGO 2009 TXT PDS 36v this weekend. I installed an Alltrax XCT48500PDS, 400a solenoid, and 2g cables from ScottyB. I know Scotty set it to stock before it shipped so the Alltrax should be working.

I double checked all connections, diodes etc. Battery pack has 36v + (i have old antique VOM with needle). Placed tow/run switch in run. I turned on the the key. There is no indicator light on the Alltrax. I pulled the c1 connector and checked the key switch pins and they test ok when key is turned on. I have voltages on all the ALLTRAX spades. No solenoid clicking. The voltage meter on the dash is not lit. I do have lights, horn, and turn signals.

I have no idea where to look without indicator faults. Help.

Thanks.

Shawn
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Unread 11-04-2019, 02:20 PM   #2
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Default Re: EZGO PDS - New ALLTRAX XCT48500 and 400a solenoid install. no light - newbie

You really need a DVM to work on your cart, but we might be able to figure it out with an analog meter.

With the battery charge disconnected from cart.
All wiring harness plugs connected to XCT
Run/Tow switch in Run
Direction selector is F
Keyswitch On

What is the voltage on J1 Pins 1, 2, 3, 4, 5, 6, 7, 8, 9 and 10 ? (J1 is called C1 on Alltrax Schematics)
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Unread 11-04-2019, 04:03 PM   #3
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Default Re: EZGO PDS - New ALLTRAX XCT48500 and 400a solenoid install. no light - newbie

Can you post a pic or 2 of the install. Sounds like you (may have) forgot to reconnect the red power lead on the solenoid big terminal? Or you got the small diode backwards? Pics will help
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Unread 11-04-2019, 11:23 PM   #4
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Default Re: EZGO PDS - New ALLTRAX XCT48500 and 400a solenoid install. no light - newbie

Thanks for the responses. JohnnieB I will get some voltage readings to you tomorrow. ScottyB I will post pics. No red wire is correct, and diode is correct. Talked with Alltrax support and did connectivity test on controller. All is good as far as controller. Will post more. Thanks...more to follow :)
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Unread 11-05-2019, 07:40 PM   #5
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Default Re: EZGO PDS - New ALLTRAX XCT48500 and 400a solenoid install. no light - newbie

JohnnieB:

I tested all the J1 Connectors:

Pins 4,5,10 have 36v + The rest are 0v.

I ordered a DVM also.

ScottyB

Pictures attached.

Thanks,

Shawn
Attached Images
File Type: jpg 20191105_151848.jpg (212.5 KB, 0 views)
File Type: jpg 20191105_151803.jpg (203.3 KB, 0 views)
File Type: jpg 20191105_151740.jpg (226.2 KB, 0 views)
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Unread 11-05-2019, 07:50 PM   #6
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Default Re: EZGO PDS - New ALLTRAX XCT48500 and 400a solenoid install. no light - newbie

Look on page 16 of the owners manual at the PDS install diagram. There is a red wire on the big solenoid post with the main battery cable. I don't see this with your cart
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Unread 11-05-2019, 08:50 PM   #7
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Default Re: EZGO PDS - New ALLTRAX XCT48500 and 400a solenoid install. no light - newbie

It is there on the 1st pic from above. Yellow compression ring connector. Right side. Had to change ring so it would fit the big post. Third pic it is on the lower side of pic.

Shawn
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Unread 11-06-2019, 11:18 AM   #8
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Default Re: EZGO PDS - New ALLTRAX XCT48500 and 400a solenoid install. no light - newbie

Quote:
Originally Posted by greenguru View Post
JohnnieB:

I tested all the J1 Connectors:

Pins 4,5,10 have 36v + The rest are 0v.

I ordered a DVM also.

ScottyB

Pictures attached.

Thanks,

Shawn
Run/Tow switch is in Tow, or switch is bad, or J3 not plugged in.

Attached is a schematic of a XCT in a PDS and a drawing showing the voltage paths through a stock PDS controller. The XCT has similar voltage paths.
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File Type: jpg XCT-PDS with regen diode.jpg (213.2 KB, 0 views)
File Type: jpg Voltage paths through PDS controller.jpg (138.9 KB, 0 views)
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Unread 11-06-2019, 03:07 PM   #9
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Default Re: EZGO PDS - New ALLTRAX XCT48500 and 400a solenoid install. no light - newbie

At a glance. The red wire I mention looks to power the R/T switch.
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Unread 11-06-2019, 04:38 PM   #10
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Default Re: EZGO PDS - New ALLTRAX XCT48500 and 400a solenoid install. no light - newbie

ScottyB

The red wire goes down to the harness. The middle picture is the wire. Looking at the wiring diagram the red wire then goes to C1 - 5. C1 - 5 has 36v + on it. I assume c1 - 5 gets power through the red wire from the + side of the solenoid.


The run/tow seems to work when i flip the r/t up pin c1 - 4 has 36v. When I flip the r/t down c1-4 has 0v. I did find 36v+ on c1-9. I may have missed that in my previous measurements.

So with the r/t switch up i have 36v on pins 4,5,9,10. With the r/t down I get 5,9,10 with 36v.


Do you or JohnnieB have a list of what voltage each pin should read?

Thanks,

Shawn
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