2010 ezgo txt 48v no solenoid click no movement

[Bdlebo]

Just upgraded my 2010 EZGO TXT 48v with new Alltrax XCT 500 amp controller along with the monster sized SW200 solenoid EV Drives paired with it. I also replaced stock wires with new 2 gauge wiring. Wired everything according to what Alltrax diagram shows. I turn key switch on the controller lights up to a solid "green". However, when I put the switch in forward there is no movement or click from the solenoid. Same thing when I put it in reverse, no movement, but it does emit the solid beep sound. I checked voltage on large solenoid terminals and it reads the same for both. Checked small terminals as well and they read same voltage as large terminals. When I depress pedal with key and run/tow switch on and volt meter hooked up, there is no variation in voltage readings. (Not sure if there should be or not) Any suggestions? Possibly wired something wrong, bad new solenoid or failed to hook something up? Also, there is a gray colored wire coming off of the charging block that is cut and used to go to the "positive" side of battery pack. Cart worked before without it prior to controller/solenoid upgrade. Should I reconnect? New to all this, so any suggestions is greatly appreciated.

Lebo

[Bdlebo]

UPDATE: Additionally I found that when I turn the key on and roll the cart back and forth, the solenoid clicks and the cart emits a beeping sound. This is racking my brain!

[JohnnieB]

The symptom is that the solenoid does not click when pedal is pushed, so problem is in the solenoid activation circuit. (Looking at the high current circuit at this point is chasing your tail.)

The solenoid clicks when cart is pushed (Walkaway Safety function) so the solenoid and that part of the controller is good.

LED turns a solid green without a computer connect to controller via the USB port, am I correct?

If so, the Run/Tow switch and Keyswitch are working.

That leaves the pedal switch and F/R switch.

Oops, you said beeper sounds when F/R is in R, so the F/R switch is good, or at least the R side of it.

Measure the voltage on Pin-6. Should go to full battery pack voltage(~51V when fully charged) when pedal is pushed.


While you are there, also check Pins 5 and 9 for full battery pack voltage.

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The grey wire is a battery temperature sensor and is not needed to run cart.

[Bdlebo]

Yes, LED on controller flashes green 4 times when key is turned on and then goes to a solid green. Ill check the pins and let you know how I make out. I appreciate the info very much.

[Bdlebo]

Additionally, when I have the laptop hooked up to the controller it's not indicating any errors under the "Monitor" tab when I go through the process of turning the key on and pressing the pedal. Also no errors indicated when I manually push the cart and make the solenoid click and beeper beep.

[scottyb]

Just for grins try reconnecting the gray wire to the battery pack +

[Bdlebo]

Ok, tested the wires at the harness. Pins 5 & 9 both show 51.4. Tested pin 6 with key on pedal depressed, with and without F/R switch. Readings there showing 0.00

Reconnected gray wire as well and no change.

[Bdlebo]

Tested green wire right at the micro switch and it goes from 0 to 51.4 when pedal is depressed.

[JohnnieB]

Either pack voltage isn't getting to the pedal switch, or isn't getting from pedal switch to controller Pin-6, or the pedal switch is bad.

[JohnnieB]

Originally Posted by Bdlebo

Tested green wire right at the micro switch and it goes from 0 to 51.4 when pedal is depressed.

I'm not sure it a TXT-48V has it, but older carts had an inline connector between the cable coming out of pedal box and the carts wiring harness. It caused all sorts of problems.

Anyway, the voltage is good through the pedal switch. Fix the green wire from the pedal switch to Pin-6 and the cart most likely will be running.