Customer cart

[Andy4639]

Customer cart is a TXT series. Put a SR 400amp 36 volt altrax controller in it back in August of last year. Cart has ran fine until this past weekend. I went over today and hooked the laptop up to it and got the 4 green lights and then solid green. Checked everything had no codes that I saw.
The cart want move at all. No statues light at all unless I hook the laptop to it.
I checked voltage and the small activation wires on the solenoid are working but the controller isn't powering up nothing. The solenoid makes no sound at all when I turn the key on and press the gas pedal but the voltage passes through the 2 small terminals according to my voltmeter anyway. I didn't check the white & black though form the ITS to the controller.???
But shouldn't the statues light come on from the Key switch being on & pedal being pressed?
I told them to bring it to the house and I would take a better look at it.
Any thoughts on what to look for?

[kgsc]

If there is power on b+ and b- as well as the + and - of J1 I would think that the controller has issues.

[handtools]

ITS micro switch? Molex connector between pedal box and controller? Pretty much check the activation circuit until you find out where you lose power.

[JohnnieB]

Here's a schematic with the KSI voltage path highlighted.

No shown on it is the in-line connector at the end of the gray cable from the pedal box.

There is a red wire from the solenoid coil to the controller's KSI (Red) jack that turns on the SR.

[Andy4639]

Ok they dropped the cart off today and here are some screen shots. If I hook the computer up it will flash 4 green over and over but never goes solid. If I disconnect the computer nothing. If I ground the solenoid to the battery pack it clicks with the gas pedal but nothing happens. I get 39+ on B+ .
Taking the black & white wires loose at the controller and I get all kinds of crazy voltage readings.

[JohnnieB]

The SR is partially powered up by the +5V in the USB connection. Only the logic circuits are active, which includes Toolkit's monitoring screen.

When USB is connected, the LED repeatedly blinks which throttle type is selected - 4 flashes = EZGO ITS.

The monitor screen shows the Keyswitch Input is ON, so the is pack voltage on the KSI jack. Also shows a battery voltage that is above the set points, so B- is connected and B+ is connected, which means the SR ought to be powering up when pedal is pushed.

Contact Alltrax, they may have some more tests, but I suspect the SR is bad.

Added:
Doesn't need the ITS sensor to power up.

[Andy4639]

Originally Posted by JohnnieB

The SR is partially powered up by the +5V in the USB connection. Only the logic circuits are active, which includes Toolkit's monitoring screen.

When USB is connected, the LED repeatedly blinks which throttle type is selected - 4 flashes = EZGO ITS.

The monitor screen shows the Keyswitch Input is ON, so the is pack voltage on the KSI jack. Also shows a battery voltage that is above the set points, so B- is connected and B+ is connected, which means the SR ought to be powering up when pedal is pushed.

Contact Alltrax, they may have some more tests, but I suspect the SR is bad.

Added:
Doesn't need the ITS sensor to power up.

Thanks JohnnieB.
I will be calling them in the morning.

[Andy4639]

I called and they are out of the office for 2 weeks!

I got e-mails from them though asking questions that I had already answered but...now I'm waiting on another e-mail reply. I'm pretty sure the controller has gone out.