97 EZGO TXT - Alltrax XCT400DCS/200 SOL Upgrade - Wiring check

[JeremyH]

Greetings,
I'm working on converting my OEM 97 EZGO TXT DCS to the Alltrack XCT400DCS with the 200amp solenoid.

The original solenoid on the smaller terminals had the following:
Small terminal close to large +: Blue wire from main wiring bundle
Small terminal opposite to large +: Yellow and Red wire from main wiring loom & another yellow wire coming in from below.


On the new XCT400DCS, I have all the large wires set correctly, I'm just a bit confused on the 200amp solenoid.

Right now I have the small diode setup on the SW180 side where it goes from - to + just like the instruction says. I also have the larger diode that was included on the top terminals matching the instructions. On the OEM solenoid there were two small red wires connected to the large + post, which I've carried over to the large + post on the new 200amp.

The remaining smaller wires have me confused. Do I put the blue on the + side opposite the diode and then combine the red and two yellows and connect them to the - side opposite of the diode?


If I go with that setup and key on, set the Run/Tow to Run, the system flashes a 2G/5R light setup saying Low Throttle Over Range.

Looking for some help/clarification on the setup. Thanks!

[LabRat]

the strip on the diode goes toward the post with 3 wires, these are the positive signal

[kgsc]

Blue is negative. Red, yellow and white/yellow are positive. Diode stripe lead is on the positive.

[JeremyH]

Ok, I switched the blue to negative and the 3 wire to positive. Verified thenstripe on the diode is to the +.

Still getting the 2G/5R code

[mgray70]

Check the throttle setting on the program. It should be factory set for ITS throttle, but I have seen them come from the factory set to something different.

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[scottyb]

Check the motor field wires for shorts here >
This is a common problem

[JeremyH]

Installed the Alltrax toolkit and think I found the issue. Looks like the ITS might be bad.

When I key on the cart, throttle shows 100%/full green even though I'm not touching the throttle.

Grabbed my VM and probed the white & black wires at the Alltrax connector and at the ITS itself under the mat. According to what I could find on CU's site, with the Alltrax, I should go from 10v to 6v.


ITS Throttle
White & Black wires voltage @ Alltrax connector:
No throttle: 7.22v
Full throttle: 4.32v


White & Black wires voltage @ ITS:
No throttle:7.22v
Full throttle:4.32v



I also checked with White wire and B-
Alltrax:
No Throttle: 7.96v
Full Throttle: 5.74v

ITS:
No Throttle: 7.96v
Full Throttle: 5.74v

Replace the ITS unit?
Any other tests I can do to confirm the ITS? (bypass, etc.)

[mgray70]

Unplug the ITS and recheck the throttle output on the controller. If it is 10 volts it's possibly the ITS. Did you check to see if it was set to ITS throttle?

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[mgray70]

Originally Posted by mgray70

Unplug the ITS and recheck the throttle output on the controller. If it is 10 volts it's possibly the ITS. Did you check to see if it was set to ITS throttle?

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Never mind the question. I just looked closer at the picture and got my answer.

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[JeremyH]

I unplugged both black and white from the ITS and checked the white/pin1 at the controller and I get 10.39v.