Ezgo with alltrax controller problems

[Jrdutton32]

So I took the resistor off and my silonoid isn't welded the clicking I mentioned is coming from the silonoid. It does give me 4 flashes the a green light. But when I press the throttle the led just stays green and didn't turn orange or yellow. So what's my next move?

[JohnnieB]

DCX controllers will often energize the solenoid momentarily when they power up, and in a PDS they power up when the key is on and a direction is selected.

Do that and wait until the solenoid de-energizes, then push the pedal, Does the solenoid click when the pedal is pushed?

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Shotgun approach. Disconnect and reconnect the 10-pin connector on top of controller and the four sets of control wiring that plug into the adapter.

Sorta sounds like a control wire issue and the PDS to DCX adapter is a plumber's nightmare.

[Jrdutton32]

The silonoid did click when the key or the foward/reverse switch is cycled but does not click when the throttle is pressed, I have unplugged all the connections and put dialectic grease except fir the big main plug

[scottyb]

I think it's one of 2 problems.
1. pedal box micro switch bad. = replace it
2. controller bad. replace it or ... replace the Negative side of the activation circuit with a constant supply

If you are ready to upgrade check out the link below

[Jrdutton32]

Is there a way to test the pedal box?

[JohnnieB]

Here is a schematic with the pedal switch voltage path highlighted.

The controller is powering up, so most of it is intact.
Find J4 (4 pins in single row) and with everything connected, measure the voltage on the backside of Pin-2.

That is the voltage source to the pedal switch and should be close to full battery pack voltage (about 0.6V less than full pack voltage due to the voltage drop of one of the two diodes in the adapter).

J4 Pin-1 is the switched side of the pedal switch. Should be 0V with pedal up and nearly pack voltage when pedal is pushed.

[Jrdutton32]

I measured voltage on pin 2 (yellow wire)has full pack voltage -.6 volts so that looks ok. But when measuring pin 1 (green wire) I get 0 voltage no matter where the throttle control is.

[scottyb]

Test the wire for continuity between J1 pin 1 and J3 pin 4

[JohnnieB]

Originally Posted by Jrdutton32

I measured voltage on pin 2 (yellow wire)has full pack voltage -.6 volts so that looks ok. But when measuring pin 1 (green wire) I get 0 voltage no matter where the throttle control is.

Okay, good voltage on J4 Pin-2, but not on J4 Pin-1 with pedal up or down says there is a bad pedal switch or bad wiring between the pedal box and controller adapter.

There is an in-line connector between the cable that comes out of the pedal box and the wiring harness to the controller that cause problems. It'll be in the general vicinity of where the cable is routed through the frame in front of the batteries. Not all cart have this connector.

If your cart doesn't, lift the floor-mat and open the pedal box. (Picture of opened pedal box attached)

[Jrdutton32]

Ok ill check the switch box this evening