'03 TXT with PDS died

[rickmyers]

Have a 03 TXT that the grandkids were in and it died. Pulled it back to garage with tractor, but not in tow mode (speed < 10 mph). Looked thru old threads and checked all that I could find that applied. Key on, batts up (36.75v) F/R switch does not beep any longer. Can't get to diag mode since no beep?

J1 pins 4&5 pack voltage
J4 pin 1 0v pedal up/ 36.74 down
J4 pin 4 36.74 pedal up / 36.74 pedal down.

Solenoid has 36.06 on left post, 36.75 on right, no difference with pedal.

Any ideas would be greatly appreciated. Used to haul feed. Grandkids now banned!

Rick

[scottyb]

J4 pin 1 and 2 is the pedal box micro switch
(+) power out on one and in when the peddle is depressed on the other.


Maybe a bad ms in the pedal box? Grand-kids exonerated

[kgsc]

Here is a link to a diagram for some trouble shooting but if J4 Pin 1 has 0 volts pedal up and 36+ pedal down, I would think the MS is working. Also think 36+ is high on pin 4..

http://www.buggiesgonewild.com/elect...-diagrams.html

[rickmyers]

Would a bad direction switch cause this? Wondering since I get no beep in reverse. Way to test or bypass for testing?

[kgsc]

Did beep stop because of this ? If so, Pointing towards controller. If not, can you hook it back up ? To put it into diag mode, turn key to off and cycle the FnR switch from N to R 5 times landing on N. Should beep to tell you what mode it is in.

And yes you can bypass the switch by crossing the appropriate wires from the diagram. Those switches do fail but normally not both directions at once..

[scottyb]

Pin 3 & 4 is the ITS signal.
on a stock cart DVM (-) probe to pack main (-)
probe the white wirepin 4 and read 1.0v when the solenoid clicks and 2.7v with the pedal all the way down.




Depending upon how far you towed it, and how lucky or unlucky you are today ... the controller may be destroyed by the towing in run mode.



Once you can confirm proper power and throttle signal we can test controller output.

[rickmyers]

Just tried JohnnieB's universal troubleshooting guide from Jun 2011.

Battery pack at 36.75 v

B- and A1 show 36.08 with pedal up or down. Does not decrease to 0. Throttle signal problem? and if so, how do I test that? can wire a house in a heartbeat, but not so good with finding issues like these.

Hate to start replacing parts willy-nilly without knowing what's really wrong and how to keep it from recurring if it was a grandkid-caused issue.

[rickmyers]

White pin J4 at 2.05 v up or down. Just realized the solenoid isn't clicking. It's something in the throttle box. Should the regular 4 post solenoid being clicking too? Now I feel really dumB!!!!!

[JohnnieB]

Having 36.74V (Pack voltage) on J4 Pin-4 sounds like a bad controller.

Here are a couple cut&pastes from the PDS manual

[JohnnieB]

Originally Posted by rickmyers

White pin J4 at 2.05 v up or down. Just realized the solenoid isn't clicking. It's something in the throttle box. Should the regular 4 post solenoid being clicking too? Now I feel really dumB!!!!!

Didn't see this prior to last post, but White wire is on J4 Pin-4 according to the schematic, so it ought to be 15V +/- 1V and if it is out of range above or below, the controller is probably bad.

Solenoid not clicking and beeper not working also point in that direction.

Drop a DCX500 in it and back it off to 350 or 400 Amps and it will haul a lot of feed without overheating the controller. It'll go a bit faster too.

BTW: Pulling when not in Tow mode turns on the regen braking at max, so that may be what took out the controller rather than the grandkids, however, the reason why it stopped working while they were driving may still exist.