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Old 12-22-2012, 11:56 AM   #1
devybob
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Default I think i did it again!

I can't believe I did it again,I flicked the headlights on after installing a voltage reducer and I heard a puff,and smelled a stink and the cart is dead.I just installed a new alltrax dcx400 with 4 gauge cables and a HD solenoid and I think I need a new 410 dollar controller. I don't know how to check to make sure it is the controller,so I'm stuck on what to do next. So much for being proud of the cart running so good after the new controller. I will not install a new voltage reducer since my troubles started after the installation. Can someone tell me how to check to make sure it's the controller.It's out of the cart now, but putting it back for checking purposes is no big deal.
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Old 12-22-2012, 03:25 PM   #2
devybob
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Default Re: I think i did it again!

Maybe not.This time it's different,I have power going to the key switch in reverse,the last time I blew up,I had nothing. Can someone tell me where to start?
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Old 12-22-2012, 04:33 PM   #3
devybob
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Default Re: I think i did it again!

OK I have reverse! Everything works in reverse.
Too bad I don't have the same luck in forward. I have no power to the solenoid or in the battery gauge when I switch to forward.
The alltrex error code shows 4 green lights in reverse,but nothing in forward.
I think I'll try the forward and reverse switch to see if I can make heads or tails of this.
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Old 12-22-2012, 09:25 PM   #4
beach cart
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Default

I don't mean to be a smart a__. But do you think maybe its time for some professional golf cart mechanic help. It maybe cheaper and you can learn what he did or maybe tell exactly what and how your doing it for help. I maintain my cart, I have learned tons from all the builds and especially johnnie b and Scotty b. There posts and others builds and others have given a fledging cart fixer to try more complex things. If your just venting disregard my reply.
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Old 12-22-2012, 10:18 PM   #5
devybob
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Default Re: I think i did it again!

Maybe you're right beach cart, I'm not as steady as I used to be,but I'm still willing to learn and if it costs me extra bucks,so be it. I have the willingness of a 20 year old to learn in the body of a 70 plus.My errors seem to be from being clumsy,but I won't give up trying. I'm still looking for help.
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Old 12-22-2012, 10:46 PM   #6
kgsc
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Default Re: I think i did it again!

Break out the DVM and start checking.. If I remember correct, 42vt Western ? PDS system ? May have a bad diode or bad wire in the PDS conversion harness. The fact that it works in reverse could be a good sign
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Old 12-22-2012, 11:28 PM   #7
devybob
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Default Re: I think i did it again!

I put the controller back in my 42v western cart. If the diode you're talking about is the one across the solenoid, I checked that out and it's good.As far as checking out the harness, the only way I know of is to have power through the solenoid and in forward, but I have nothing in forward.The only way to get the solenoid activated is in reverse.How do I check from here. BTW when the solenoid is activated (in reverse)the green light on the controller gives 4 flashes and then is a steady green.According to alltrax, this means all is good.
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Old 12-22-2012, 11:48 PM   #8
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Default Re: I think i did it again!

do you have two micro switches on the F/R switch, one for forward and one for reverse??, if so check the forward micro, it could be bad
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Old 12-23-2012, 06:17 AM   #9
JohnnieB
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Default Re: I think i did it again!

Check the diode between pins 3 and 9 on the PDS adapter.

Hint: There are steering diodes between pins 2 & 9 (Reverse) and pins 3 & 9 (Forward) that forward B+ to pin 9 to supply B+ to keyswitch and tell controller to turn on when either F or R is selected on F/R switch.

If the controller powers up in Reverse and everything functions normally, the problem has got to be in whatever tells the controller to turn on and run in Forward. Problem could be the F/R switch, a steering diode or wiring, or something I missed......



FWIW: Rib, is on the right path, but on a series cart instead of a PDS type drive system.
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Old 12-23-2012, 08:30 AM   #10
devybob
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Default Re: I think i did it again!

Right on!!!! One of the diodes on the adapter harness is blown. It looks like I could just replace the diode.I assume that it would have the same value as the other diode right next to it on pin 2. I don't know how to read the value of diode, but maybe you could tell me,or maybe someone at radio shack can read it, or should I just try to call alltrax and order a new harness?
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