??? for ScottyB

busman9 · 03-22-2015, 07:11 PM

Scotty,I have a 1999 Series cart that at time will not go. The solenoid clicks but the cart does not go. I have been reading and running test and have not figured it out. I have Alltrax 4844 controller,200A solenoid and H/D FR control all from you. I am attatching photos of the switch for you to llok at,Does it look OK? When the cart acts up if you keep working the gas pedal it will finally take off and run fine. I also had PQ overhaul the motor hoping that was the the problem but not!

scottyb · 03-22-2015, 08:02 PM

If working the gas pedal makes the cart go eventually then the switch is not the trouble (looks okay)
But first things first .... Does the solenoid click when the cart will NOT go? The trouble could be in the pedal box micro-switch or the wire connections between the ITS unit and the controller.

cableguy_hd · 03-22-2015, 08:08 PM

I had the same issues and it was my controller. If the solenoid clicks but no go does the light on the controller light up?

busman9 · 03-23-2015, 06:06 AM

I took the pedal micro-switch out and tested with a meter several times (75) and it never failed. I tested the wires at the controller ( black and white) and the voltage check good. I have cleaned the connector 2 times with no change. I have not observed the green light on the controller when the problem happens,I will try to do that.

cableguy_hd · 03-23-2015, 06:19 AM

here is my thread. not sure if you looked at it. maybe it will help
http://www.buggiesgonewild.com/elect...eshooting.html

post 2 & 9 may help. check for pack voltage on the plug on the controller at the red wire. if you have pack voltage when the solenoid clicks on that pin and the green light on controller doesnt light up you have a bad controller. take it out and call alltrax. they will want info off of it. look for the mfg date and hope its less than 2 years ago cause if they deem it bad all it will cost you is the ride to get it to them. for me it was 19$ but it beats the hell out of 325$.

scottyb · 03-23-2015, 08:47 AM

If the controller is showing a solid green light that turns orange when you go to full throttle and there is no red flashing LED code then it's likely the controller is working and the problem is somewhere in the high amperage delivery system.

Inspect and pull test all cable ends. Reassemble F&R with enough tension to make it hard to shift. Perform continuity tests on the F&R per instruction below.

busman9 · 03-25-2015, 08:03 PM

I have reassembled the F/R switch and run the continuity test and it is good. Reassembled the cat and run some voltage test that Johnnie has posted in other threads. Now I am really confused???? Black/White wire at controller
.694V with no pedal
8.79 V when solenoid clicks
5.79V at full throttle
unplug the ITS connector and 1.016V ???????????????????????????????
The light on the controller is green while accel. and orange at full throttle.
The cart DID NOT act up while doing all test. What is the next test?????
THANK YOU FOR ALL THE ADVISE!

JohnnieB · 03-26-2015, 09:19 AM

Quote:

Originally Posted by busman9

I have reassembled the F/R switch and run the continuity test and it is good. Reassembled the cat and run some voltage test that Johnnie has posted in other threads. Now I am really confused???? Black/White wire at controller
.694V with no pedal
8.79 V when solenoid clicks
5.79V at full throttle
unplug the ITS connector and 1.016V ???????????????????????????????
The light on the controller is green while accel. and orange at full throttle.
The cart DID NOT act up while doing all test. What is the next test?????
THANK YOU FOR ALL THE ADVISE!

If the cart wasn't misbehaving, the voltage readings cannot tell us what the problem is that cause the cart to misbehave.

That is why intermittent problems are so hard to troubleshoot. You can only find them when they exist.

-------------
In a series cart, the controller doesn't power up (LED illuminated) until the pedal is pushed, so there will be little, if any, voltage between the black and white (ITS) wires until pedal is pushed far enough to make the solenoid click.

The voltage when the solenoid clicks is a bit low, so the plunger that goes into the ITS sensor may need adjusting, but all that would do is make it jerk when trying to take off from a standstill. The pedal on the floor voltage is about right, so you ought to get a 100% duty cycle out of the controller. (The LED turning orange says you are.)

With ITS wires disconnected, I'm not sure what the voltage would be.

------------
While the cart is acting up, check if the solenoid clicks and the LED illuminates when the pedal is pushed.

busman9 · 03-26-2015, 02:51 PM

When the cart acts up the solenoid does click,the LED flashes.

JohnnieB · 03-26-2015, 03:09 PM

Quote:

Originally Posted by busman9

When the cart acts up the solenoid does click,the LED flashes.

Okay, that says the the solenoid activation circuit and the controller are most likely good, so go back and read post#6 from scottyb.

03-22-2015, 08:02 PM	#2
scottyb Happy Carting Join Date: Dec 2007 Location: Southern California Posts: 73,417	Re: ??? for ScottyB If working the gas pedal makes the cart go eventually then the switch is not the trouble (looks okay) But first things first .... Does the solenoid click when the cart will NOT go? The trouble could be in the pedal box micro-switch or the wire connections between the ITS unit and the controller.

03-22-2015, 08:08 PM	#3
cableguy_hd Gone Wild Join Date: Nov 2011 Location: Danville,Va. Posts: 654	Re: ??? for ScottyB I had the same issues and it was my controller. If the solenoid clicks but no go does the light on the controller light up?

03-23-2015, 06:06 AM	#4
busman9 Gone Wild Join Date: Jan 2011 Location: mascoutah,il Posts: 387	Re: ??? for ScottyB I took the pedal micro-switch out and tested with a meter several times (75) and it never failed. I tested the wires at the controller ( black and white) and the voltage check good. I have cleaned the connector 2 times with no change. I have not observed the green light on the controller when the problem happens,I will try to do that.

03-23-2015, 06:19 AM	#5
cableguy_hd Gone Wild Join Date: Nov 2011 Location: Danville,Va. Posts: 654	Re: ??? for ScottyB here is my thread. not sure if you looked at it. maybe it will help http://www.buggiesgonewild.com/elect...eshooting.html post 2 & 9 may help. check for pack voltage on the plug on the controller at the red wire. if you have pack voltage when the solenoid clicks on that pin and the green light on controller doesnt light up you have a bad controller. take it out and call alltrax. they will want info off of it. look for the mfg date and hope its less than 2 years ago cause if they deem it bad all it will cost you is the ride to get it to them. for me it was 19$ but it beats the hell out of 325$.

03-25-2015, 08:03 PM	#7
busman9 Gone Wild Join Date: Jan 2011 Location: mascoutah,il Posts: 387	Re: ??? for ScottyB I have reassembled the F/R switch and run the continuity test and it is good. Reassembled the cat and run some voltage test that Johnnie has posted in other threads. Now I am really confused???? Black/White wire at controller .694V with no pedal 8.79 V when solenoid clicks 5.79V at full throttle unplug the ITS connector and 1.016V ??????????????????????????????? The light on the controller is green while accel. and orange at full throttle. The cart DID NOT act up while doing all test. What is the next test????? THANK YOU FOR ALL THE ADVISE!

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03-26-2015, 02:51 PM	#9
busman9 Gone Wild Join Date: Jan 2011 Location: mascoutah,il Posts: 387	Re: ??? for ScottyB When the cart acts up the solenoid does click,the LED flashes.