2001 Ezgo Pds alltrax controller help

[yurtle]

Have you plugged your laptop into the controller, to see what inputs it is receiving and what outputs it's sending in response to the inputs?

Throttle troubleshooting from the Stickies:

http://www.buggiesgonewild.com/elect...e-testing.html

Like I said, I'm a series guy, but I'd bet the troubleshooting chapter in the manual is the same for any controller, with the exception of the throttle signal, above. All other input is a number of switches, which are open or closed. The output goes from the controller to the motor. The motor has no clue whether the controller is stock or Alltrax. The only thing different is possibly the map. However, since it sometimes works normally, I'd guess your map is OK.

So...

Throttle signal?

One last thing to check are motor brushes. They may have a lot of miles on them, and checking them is pretty straight forward, following the manual.

[JohnnieB]

Originally Posted by Bray6092

Pack voltage 38.8

Yes it’s dirty had planned on cleaning it today.

Just wasn’t sure what would cause it run sometimes.

1. The crawl speed isn’t even a crawl if any incline it stops.

2. Light is solid green in controller when pedal is pushed

1. Sounds like controller output isn't going to 100%, but could be brushes.

2. Look at LED on controller when NCX powers up. Key-ON and Direction
selected. You should get four green flashes , then a solid green. When you push pedal all the way to the floor, the LED should turn yellow.

-------------
Lift rear tires off ground and put on jackstands, so the half ton cart doesn't take off unexpectedly and run over someone or something.


Find the gray cable from pedal box and measure voltage between pins 3 & 4 (black and white wires) while plugged in to the adapter wiring. You should get 10V with pedal up and 6V with pedal down. What are you getting?

Attached are the error code listing and a schematic. (NCX is a non-programmable version of the DCX)

[Bray6092]

4 blinks green
Solid green
Pedal press stays green

[JohnnieB]

Originally Posted by Bray6092

1. 4 blinks green
2. Solid green
3. Pedal press stays green

1.
2.
3. Not going to 100% throttle. Check voltage between black and white wires at plug on end of cable from pedal box while all plugs are plugged in.
10V pedal up and 6V with pedal on floor.

[yurtle]

Would a laptop help, since this is an Alltrax?

[Bray6092]

I get zero Volts just checking white and black wire at controller (red post on white black post on black)


With voltmeter on neg battery

Black Wire 13.1 then 10.7

White wire. 13.1 then 0.0 (I check this multiple times definitely goes to zero)

[Bray6092]

Does this mean controller is working

[JohnnieB]

Originally Posted by Bray6092

I get zero Volts just checking white and black wire at controller (red post on white black post on black)


With voltmeter on neg battery

Black Wire 13.1 then 10.7

White wire. 13.1 then 0.0 (I check this multiple times definitely goes to zero)

From my earlier post:

Find the gray cable from pedal box and measure voltage between pins 3 & 4 (black and white wires) while plugged in to the adapter wiring. You should get 10V with pedal up and 6V with pedal down.

The EZGO ITS sensor draws more amps (milliamps actually) as the plunger is inserted into it further and the Alltrax controller feeds the ITS sensor with a constant current source, so the voltage between the black and white wires decreases as the sensor draws more amps. The voltage is not referenced to the battery pack negative.


Also, pedal up means pedal pushed just far enough to make solenoid click.

[JohnnieB]

Originally Posted by yurtle

Would a laptop help, since this is an Alltrax?

It does give Throttle Position but I'm not sure if a NCX can be connected to a computer and I'm not sure if the Alltrax program used will run on anything after Win-XP, or if you can still find the USB to 9-pin serial adapter needed.

[yurtle]

Originally Posted by JohnnieB

It does give Throttle Position but I'm not sure if a NCX can be connected to a computer and I'm not sure if the Alltrax program used will run on anything after Win-XP, or if you can still find the USB to 9-pin serial adapter needed.

The "legacy" software for AXE controllers will run on Win10. I assumed NCX was around the same time a s the AXE, but dunno. Alltrax has two recommended DB9 to USB adapters cables. But it may not be worth it. We'll see if his readings are in range when he measures what you told him, and what was in the "Throttle troubleshooting" post by ScottyB in the stickies.