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Unread 05-29-2011, 06:31 AM   #1
Not Yet Wild
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Join Date: May 2010
Location: Alabama
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Default all new parts and still no go

I know this is a long post but i dont know any other way of describing my problem!
Here is the problem that i am having. When i turn the key on and put the lever in reverse, the wheels turn about 1/8 of a turn and stops. I can switch it over to forward and nothing happens. I have to turn the cart off and then back on to get it to do the same thing again. It will never seem to want to go forward at either time. Here is a list of everything that i have done to this cart. There are probably some other things that i have done but has slipped my mind as of now.
1- New 500amp controller from D&D
2- New high torque motor from D&D
3- HD solenoid
4- HD forward and reverse switch
5- New 1A,100volt diode(white band toward power)
6- New pre charged resistor
7- New potentiometer
8- All cables are #2 gauge welding cable with brass connections
9- Main fuse installed on positive side of first battery
10- All wire connections have been replaced with new spade and loop connections and wire has also been replaced

Things that i am not sure of.

1- When i turn the switch on and push the accelerator down, i am getting seven green blinks and the solid green after that on the controller.
2- I have 6 trojon batteries and they all read 8.18 - 8.21 except for the first one that is giving me a reading of 3.62.
3- I am getting an overall reading of 44.5 from 1st batt. pos. to the last batt. neg.
4- IS THIS WHERE ALL OF MY PROBLEMS ARE COMING FROM?????
5- If so, Do i need to change all of my batteries or can i change out just the one bad one?
6- The charger is getting very hot, seems to be alot hotter than it should be
7- I have set the potentiometer up just like the manual said to and also adjusted the pedal as per the manual
8- I have not tried resetting the obc nor have i tried running a cable around the obc and bypassing the obc but i will if everybody thinks this could be the problem.
9- I have also taking other readings from the solenoid, the progammer and the on and off switch but things look normal, but am open for any kind of suggestions.
PLEASE SOMEBODY HELP ME OUT WITH YOUR IDEAS AND SUGGESTIONS.
Thank you,
Scott
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Unread 05-29-2011, 07:44 AM   #2
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Default Re: all new parts and still no go

It seems like your diode is reverse but you say the silver band is towards the battery. On the small leads of the solenoid you'll have a set of red wires, make for sure that the silver band is indeed on that side. Also, you need a 3A diode for that size of a controller. 1A is too small, and your resistor needs to be 470 ohm.
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Unread 05-29-2011, 10:53 AM   #3
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Location: Southern California
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Default Re: all new parts and still no go

Quote:
Originally Posted by fastride View Post
I know this is a long post but i dont know any other way of describing my problem!
Here is the problem that i am having. When i turn the key on and put the lever in reverse, the wheels turn about 1/8 of a turn and stops. I can switch it over to forward and nothing happens. I have to turn the cart off and then back on to get it to do the same thing again. It will never seem to want to go forward at either time. Here is a list of everything that i have done to this cart. There are probably some other things that i have done but has slipped my mind as of now.
1- New 500amp controller from D&D
2- New high torque motor from D&D
3- HD solenoid
4- HD forward and reverse switch
5- New 1A,100volt diode(white band toward power)
6- New pre charged resistor
7- New potentiometer
8- All cables are #2 gauge welding cable with brass connections
9- Main fuse installed on positive side of first battery
10- All wire connections have been replaced with new spade and loop connections and wire has also been replaced

Things that i am not sure of.

1- When i turn the switch on and push the accelerator down, i am getting seven green blinks and the solid green after that on the controller.
2- I have 6 trojon batteries and they all read 8.18 - 8.21 except for the first one that is giving me a reading of 3.62.
3- I am getting an overall reading of 44.5 from 1st batt. pos. to the last batt. neg.
4- IS THIS WHERE ALL OF MY PROBLEMS ARE COMING FROM?????
5- If so, Do i need to change all of my batteries or can i change out just the one bad one?
6- The charger is getting very hot, seems to be alot hotter than it should be
7- I have set the potentiometer up just like the manual said to and also adjusted the pedal as per the manual
8- I have not tried resetting the obc nor have i tried running a cable around the obc and bypassing the obc but i will if everybody thinks this could be the problem.
9- I have also taking other readings from the solenoid, the progammer and the on and off switch but things look normal, but am open for any kind of suggestions.
PLEASE SOMEBODY HELP ME OUT WITH YOUR IDEAS AND SUGGESTIONS.
Thank you,
Scott
Things highlighted in red are problems.
As Jeep said you need the higher value diode and resistor.
You need to check the programming on the controller and possibly raise the max voltage allowed because seven blinks indicates an 'over voltage' fault.
Which is nearly comical with one bad battery ~ change it out & reprogram and double check the pot output and the controller input match up. Good luck.
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Unread 05-29-2011, 11:19 AM   #4
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Default Re: all new parts and still no go

The several green blinks is not necessarily an indication of a fault, when start up the Alltrax blinks several green blinks to indicate what throttle setup it is and then goes to solid green indicating it's ready, the voltage value is low but is still enough a test on jack stands and should not come into play here.

What type of cart is this, I.E. is this a Regen or Series cart, and what type of Alltrax do you have, AXE or DCX?
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Unread 05-29-2011, 12:20 PM   #5
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Default Re: all new parts and still no go

your right!?>7 is a trouble code or a throttle type
Attached Images
File Type: jpg Alltrax trouble shooting led guide.JPG (71.1 KB, 116 views)
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Unread 05-29-2011, 01:08 PM   #6
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Join Date: May 2010
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Default Re: all new parts and still no go

Thanks for the reply. I will go back and double check every thing. I guess i need to check the diode and the resistor but that it was D&D sent me but i guess everybody can make mistakes. Will the size of the diode and the resistor also make this do that? One more thing that i need to add is that i just went to Sams Club and bought 6 brand new batteries. I know that they are not suppose to be the best batteries but at this point in the game, i have had enough of spending money on this thing. I just hooked them up and i am getting a reading of 50.9. I am going to go out there now and take pictures of every thing and try and post them.
Thanks again and hope yall that are sharp on these things can please help me get this thing running.
Scott
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Unread 05-29-2011, 01:20 PM   #7
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Default Re: all new parts and still no go

Quote:
Originally Posted by scottyb View Post
your right!?>7 is a trouble code or a throttle type
Don't be a Hater...
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Unread 05-29-2011, 02:18 PM   #8
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Default Re: all new parts and still no go

Please let me know if you see any thing wrong on these pictures. I am going to post as many as they will let me.
Thanks
Attached Images
File Type: jpg DSC_4377.jpg (149.1 KB, 23 views)
File Type: jpg DSC_4378.jpg (120.0 KB, 24 views)
File Type: jpg DSC_4379.jpg (124.9 KB, 22 views)
File Type: jpg DSC_4380.jpg (190.3 KB, 21 views)
File Type: jpg DSC_4381.jpg (111.8 KB, 18 views)
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Unread 05-29-2011, 02:30 PM   #9
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Default Re: all new parts and still no go

here are some more pictures
Attached Images
File Type: jpg DSC_4382.jpg (112.1 KB, 14 views)
File Type: jpg DSC_4383.jpg (125.7 KB, 21 views)
File Type: jpg DSC_4384.jpg (166.9 KB, 16 views)
File Type: jpg DSC_4385.jpg (116.6 KB, 14 views)
File Type: jpg DSC_4386.jpg (129.1 KB, 14 views)
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Unread 05-29-2011, 02:42 PM   #10
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Default Re: all new parts and still no go

and some more. As you can tell, i am in despirate need of help
Attached Images
File Type: jpg DSC_4387.jpg (119.9 KB, 14 views)
File Type: jpg DSC_4388.jpg (158.1 KB, 13 views)
File Type: jpg DSC_4389.jpg (116.8 KB, 13 views)
File Type: jpg DSC_4392.jpg (114.0 KB, 14 views)
File Type: jpg DSC_4393.jpg (191.8 KB, 16 views)
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