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Electric EZGO Electric EZ GO Marathon, Medalist, TXT and RXV. |
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08-06-2018, 10:48 AM | #1 |
Not Yet Wild
Join Date: Mar 2017
Posts: 19
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'Dead' Cart
Ok, I'm stumped. - 2000 model EZGO PDS Electric Cart
Early last year I replaced a fried Alltrax DCX400PDS controller. I used the opportunity to upgrade torque for hilly terrain. At Scotty's suggestion I installed an Admiral MOT-B2 8 hp motor with the new Alltrax XCT48500 controller, 400 super solenoid, and 2g cable set..... BEST UPGRADE EVER. Cart performed flawlessly with more torque and better battery life , ....for about 8 months +/-. One day, the wife went to check the trail cams, brought the cart home and parked it with no issues noted... cart hasn't run since. Batteries are charged to full capacity. I was told it wasn't likely a major component and was more likely a loose/broken wire issue. Since then in my spare time (which I have very little of, only home 2 days a week and "honey do's" consume most of that) I have searched and searched for any potential burnt/frayed/loose wiring issues... and because I couldn't find any issues I even began resorting to replacing nearly every wire harness / electrical component. To date I have replaced: Ignition Switch FWD/REV Toggle Switch Main Wire Control Harness (Wiring from Controller to Ignition switch, Rev Buzzer/Horn, Fwd/Rev Switch) 'Gas' Peddle Throttle Sensor and Micro Switch, Plus Wire Harness to Controller New 400 Amp Solenoid (but specifically not the diode jumper) I even ordered a new Alltrax controller, installed it with no luck, then removed and returned it. All parts were replaced 'one for one', same factory part numbers and great care taken to remove one wire from the old part, install on new part before removing next wire... IE no crossed wires or incorrectly installed parts. Still no luck, cart is dead. The digital battery volt meter works when the key is turned on (an stops working if cart is placed in 'Tow' mode). Headlights work. Nothing else, no reverse buzzer/horn, no status light on Alltrax controller, no solenoid 'click'.... The only electrical components I've yet to replace are the Tow/Run switch and harness, which seem like they work (at least in regard to the battery volt meter). At this point I basically have an entirely new electrical system, which I'm happy about, but the cart still wont 'power up'. What am I missing? Could it be the tow/run switch not allowing the controller to power up? |
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08-06-2018, 12:51 PM | #2 | |
Techno-Nerd
Join Date: Jun 2011
Location: West Virginia
Posts: 19,654
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Re: 'Dead' Cart
Quote:
The XCT powers up when pack voltage is applied to J1 Pin-8 from the keyswitch. You say the dash mounted battery meter turns on and off with keyswitch, so the pack voltage appears to be getting past the keyswitch contacts. I'd check the wire and connections between keyswitch contacts and J1 Pin-8 sticking out of the controller jack with a very fine toothed comb. The only other thing that comes to mind is a bad B- cable between controller and battery pack. |
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08-06-2018, 01:35 PM | #3 | |
Not Yet Wild
Join Date: Mar 2017
Posts: 19
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Re: 'Dead' Cart
Quote:
Thank you JohnnieB for the quick response. I'll definitely check those when I return home this weekend. Again, the keyswitch and wiring harness are both brand new... but it wont hurt to check that area again as I am now completely lost on anything else to look at! |
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08-06-2018, 02:42 PM | #4 | |
Techno-Nerd
Join Date: Jun 2011
Location: West Virginia
Posts: 19,654
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Re: 'Dead' Cart
Quote:
If you connect a laptop to the XCT, it will power up via the USB and you can see on the monitor screen in Toolkit if the keyswitch is talking to the controller. Also shows any error flag that are set. Attached is a screen-print of the monitor page from a very old version of Toolkit, but the later versions will have something similar. With the stock PDS controller, you have to have a direction selected on the F/R to get voltage to the keyswitch, but with an XCT all that is needed is the Run/Tow in Run and the keyswitch ON, to get it to power up. Plus a good B- connection back to the battery pack. |
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08-07-2018, 07:39 AM | #5 | |
Not Yet Wild
Join Date: Mar 2017
Posts: 19
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Re: 'Dead' Cart
Quote:
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08-07-2018, 11:35 PM | #6 |
Gone Wild
Join Date: Jan 2012
Location: Chico, California
Posts: 496
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Re: 'Dead' Cart
Did you try the laptop on the new controller you returned? Same results as with the old one? Will the controller power up on the bench with laptop?
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08-10-2018, 03:52 PM | #7 |
Not Yet Wild
Join Date: Mar 2017
Posts: 19
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Re: 'Dead' Cart
Ok guys. Finally made it home. Hooked up the PC to the Alltrax (had to download new toolkit, the old version I had couldn't "find the controller".
Everything appears to be working, at least to me, as far as wiring and such. Toolkit accurately tells me when I turn on the keyswitch, select FWD/REV, depress the peddle, etc. However, I get the following error flags when everything is powered up: Low & High Throttle Input Under-range as well as Shutdown... also, without the pedal depressed it says throttle is at 100%... is this the amount of throttle 'allowed' or is this the throttle that the controller thinks is applied??? See monitor screenshot: |
08-10-2018, 05:21 PM | #8 |
Happy Carting
Join Date: Dec 2007
Location: Southern California
Posts: 73,358
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Re: 'Dead' Cart
Sooo, lift the floor mat and open the pedal box. Look for water... or post pics so we can see what might be giving the 100% pedal signal and causing the high pedal disable safety feature aka HPD
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08-11-2018, 10:42 AM | #9 |
Not Yet Wild
Join Date: Mar 2017
Posts: 19
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Re: 'Dead' Cart
Took a bit this morning, had a stripped screw to remove from the 'floorboard'... turns out all I had to do was 'hold my tongue right' and let the blood out of one of my fingers...
Here is a picture with the pedal released (not pressed) |
08-11-2018, 10:43 AM | #10 |
Not Yet Wild
Join Date: Mar 2017
Posts: 19
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Re: 'Dead' Cart
One with the pedal pressed all the way
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