04 PDS won't power on altrax 4800

[chvybeatsford]

Well my wife's cart sat on charger for a few weeks/month. Now won't move . Key on does not light up controller.
Alltrax 4800
48v cart(was36v)

Checked yellow and white from key to controller plug and had Cont.
Checked white from key to controller had cont.

Any ideas guys. Could run tow be bad or that would light up controller either way?

[chvybeatsford]

Well found some problems.

Controller will power on with USB cable into laptop. But I get these issues in attached picture.

Any ideas.

[JohnnieB]

Try unplugging, spray cleaning and reconnecting all plugs on the controller.

Measure the voltage between the white and black wire on J4 (labeled as C4 on Alltrax schematics). Ought to be 10V with pedal up and 6V with pedal down.

Errors indicate the voltage is <6V with pedal in either position.

Note: Laptop powers up the XCT via the 5V fed to it by the USB connection. Only the logic circuits are active.

[chvybeatsford]

Originally Posted by JohnnieB

Try unplugging, spray cleaning and reconnecting all plugs on the controller.

Measure the voltage between the white and black wire on J4 (labeled as C4 on Alltrax schematics). Ought to be 10V with pedal up and 6V with pedal down.

Errors indicate the voltage is <6V with pedal in either position.

Note: Laptop powers up the XCT via the 5V fed to it by the USB connection. Only the logic circuits are active.

Will try. Also note I should have said the cart is just sitting. Nothing moving and I'm not hitting the gas pedal. Not sure if that changes things.

[chvybeatsford]

Johnny B bout to go test from black and white. Im assuming cart must be on to do that. As of now still no power. I removed the controller completely and cleaned all terminals.

1. Would the low voltage or irregular from pedal stop controller from powering on?

2. Can i bypass key switch by connecting the white and white/yellow on switch?

3. I also dont here solenoid click ,but again controller has no power? But does solenoid power controller ?

4. I think the key switch is working as per the software it says key on and if i turn key off and hit test fan it says KS must be on.

5. I check cont between white and black on charger to the interlock. it has cont from the red/wht on both white and black from charging port. Should it?

[JohnnieB]

Originally Posted by chvybeatsford

Johnny B bout to go test from black and white. Im assuming cart must be on to do that. As of now still no power. I removed the controller completely and cleaned all terminals.

1. Would the low voltage or irregular from pedal stop controller from powering on?

2. Can i bypass key switch by connecting the white and white/yellow on switch?

3. I also dont here solenoid click ,but again controller has no power? But does solenoid power controller ?

4. I think the key switch is working as per the software it says key on and if i turn key off and hit test fan it says KS must be on.

5. I check cont between white and black on charger to the interlock. it has cont from the red/wht on both white and black from charging port. Should it?

1. No. All that is needed to power up an XCT48x00-PDS is the charger disconnected from cart, Run/Tow in Run and Keyswitch ON. (With a stock PDS controller, you also had to have a direction selected on the F/R switch, but Alltrax altered the voltage path to the solenoid coil when they designed the XCT)

2. Yes, but monitor screen shows keyswitch to be working.

3. The controller powers the solenoid coil. Solenoid is not part of the XCT power up circuit.

4. Key switch appears to b working.

5. When I was teaching troubleshooting, I would crucify any of my students that used an Ohmmeter or continuity meter instead of a voltmeter. Unless the component being tested is completely isolated electrically, Ohmmeters and continuity meters will tell you more lies than a politician will.


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With cart ready to drive except for pedal being pushed, what are the voltages on all 10 pins of J1 (Called C1 on Alltrax schematics.) Voltmeter's black (negative) test lead on XCT's B- terminal.

[chvybeatsford]

Originally Posted by JohnnieB

1. No. All that is needed to power up an XCT48x00-PDS is the charger disconnected from cart, Run/Tow in Run and Keyswitch ON. (With a stock PDS controller, you also had to have a direction selected on the F/R switch, but Alltrax altered the voltage path to the solenoid coil when they designed the XCT)

2. Yes, but monitor screen shows keyswitch to be working.

3. The controller powers the solenoid coil. Solenoid is not part of the XCT power up circuit.

4. Key switch appears to b working.

5. When I was teaching troubleshooting, I would crucify any of my students that used an Ohmmeter or continuity meter instead of a voltmeter. Unless the component being tested is completely isolated electrically, Ohmmeters and continuity meters will tell you more lies than a politician will.


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With cart ready to drive except for pedal being pushed, what are the voltages on all 10 pins of J1 (Called C1 on Alltrax schematics.) Voltmeter's black (negative) test lead on XCT's B- terminal.

SO here are the readings on J1 without PC powering control( no green light on.)

10- 40.2
9-50.1
8-50.1
7-50.1
6-50.1
5-50.1
4-50.1
3-50.1
2-0.0
1-50.1

with power to controller via pc
10= 43.8
all the rest the same

Testing J4 with power on i get nothing with plug installed and when i pull plug from controller i get nothing..

Im not even sure as of now. would the controller be sending to J4 or is it the other way. Was going of a previous post u were telling him to check white and black from j4 to ese if ITS was working right. I do have that grey wire loom holding it together. was gonna replace all wires. can i check at the switch . I have the floor board up and cleaned it all real good at switch?

[kgsc]

JB is the expert here but 2 is reverse so 0 makes sense. 10 and 6 are the negatives for the reverse buzzer and solenoid so those numbers look okay. Both would go to 0 I believe if they’re operating. J4 is pedal plug correct? White black red green? Red and green are a switch and white black is ITS throttle. Plugged in and pedal pressed does the foot pedal switch show up in the monitor page ?

[chvybeatsford]

Originally Posted by kgsc

JB is the expert here but 2 is reverse so 0 makes sense. 10 and 6 are the negatives for the reverse buzzer and solenoid so those numbers look okay. Both would go to 0 I believe if they’re operating. J4 is pedal plug correct? White black red green? Red and green are a switch and white black is ITS throttle. Plugged in and pedal pressed does the foot pedal switch show up in the monitor page ?

Yes. J4 is pedal. Problem with monitor is showing 100% throttle and those error. Please see pic on first post.

Been I. Email with alltrax and did reset auto Cal and checked that it's on ezgo ITS. That didn't change anything.

So far still have no power light on controller without laptop on. Not even error flashes. Nothing. Like it's not getting power.

[kgsc]

I don’t know if the run tow plug will have power or not but the 10 pin plug has all the correct voltage. Have you checked the run tow switch for continuity? Should be 2 pairs.