1999 Ezgo HELP

[busman9]

1999 Ezgo series cart: 48400 Alltrax controller,400A solenoid,SW202 Rev Contactor
The cart quits in wet conditions. My next step is to check the pedal box for moisture. The controller does not flash any codes and the solenoid clicks. If the ITS is wet should the controller flash a code? Can I hook a laptop to the controller and se if that is the issue? The cart is stranded in the Deer Hunting woods

[JohnnieB]

Connect a laptop and look at Toolkit's monitor screen.

Are there any errors shown?

What is the battery voltage shown?

Does the Keyswitch Input go from OFF to ON when pedal is pushed?

Does the throttle graph go to 100% when pedal is on floor?

[busman9]

Thanks Johnnie,I will get back to the clubhouse and check and reply back in a few days. Thanks Again

[busman9]

Have to cart home,towed it out of the woods
No error codes
49.5V battery power
keyswitch input goes on-off
throttle goes to 100% when on the floor

[Sideways]

Battery issue?
According to Johnnieb's chart 49.5v is partially charged.

[busman9]

Voltage at the pack is 52.2
I disconnected the pre charger resistor at the big posts of the solenoid
52.2V at battery side 52.2V when solenoid clicks on controller side but when you let of the pedal the voltage does not drop to 0 it very slowly starts to bleed off. I thought it should drop off to 0??????

[JohnnieB]

Originally Posted by busman9

Voltage at the pack is 52.2
I disconnected the pre charger resistor at the big posts of the solenoid
52.2V at battery side 52.2V when solenoid clicks on controller side but when you let of the pedal the voltage does not drop to 0 it very slowly starts to bleed off. I thought it should drop off to 0??????

What you are seeing is normal.

There are a bunch of filter capacitors between the controller's B- and B+ terminals and when the solenoid contacts close, the are charged to pack voltage. For safety reasons, the capacitors have a bleeder network that discharges them in a few minutes so people don't get zapped when they pick up a disconnected controller.

The pre-charge resistor bridges the open solenoid contacts and keeps the filter capacitors charged to near pack voltage to reduce the arcing as the solenoid contacts bounce to a close, prolonging the solenoid's lifespan.

Attached is a picture of the power board in a stock PDS controller. AS you can see there are a dozen 1000µF capacitors for a total of 12,000µF between B- and B+. An aftermarket series controller will have a similar filter network.

[busman9]

where do I go next to diagnose the NO Go problem?

[busman9]

When the laptop shows 100% throttle the motor voltage is about 20V, That does not seem correct?????

[JohnnieB]

Originally Posted by busman9

When the laptop shows 100% throttle the motor voltage is about 20V, That does not seem correct?????

When the throttle is at 100%, the battery voltage shown on the Toolkit monitor screen and the motor voltage ought to be equal, or very close to it.

Verify the Max Forward Motor Speed slider is set to 100% and the Throttle Type selected is EZGO ITS.

Also verify Max Motor Amps and Max Battery Amps are set to 400.

Measure the voltage between the controller's B- and B+ terminals when solenoid is energized and compare that reading to the Battery Voltage shown on the monitor screen. Should be the same.

Measure the voltage between the controller's M- and B+ terminals and compare it to the Motor Voltage on the monitor screen. Should be the same.

If the handheld DVM readings are the same as the monitor screen readings and the Battery Voltage does not equal the Motor Voltage when Throttle is at 100%, then the controller is bad.

Contact Alltrax or the vendor you got the SR48400 from.