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Old 09-25-2013, 03:59 PM   #1
TGJR
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Default Troubleshooting multiple carts with the same problem.

I have two almost identical 48v EZGO series carts with Alltrax AXE-4865 controllers, HD solenoids and stock motors. One has Scotty's HD F/R switch, the other doesn't. All the upgraded components are only a year old. Both of them have the same problem. When they run, they run perfect. But when they decide not to, I can't figure out why. There's no pattern to it. Sometimes it is during the middle of a ride. Other times they won't run from the get-go after sitting for days. They are hunting carts used at a hunting camp so maintenance is a little sporadic and they have definitely seen rain and mud.

The controllers are getting power. The pack voltages look fine. The solenoids operate fine and deliver the pack voltage to the controller. The controller LED flashes green 3 times and then stays green so long as the pedal is down. I haven't been able test the motors but when the carts move, the motors pull strong and don't have any hesitation or unwanted sounds. I ran continuity tests on both F/R switches and they checked out fine in both forward and reverse. Micro switches and the reed switch is fine.

Can the F/R switches ohm out fine but still have an issue delivering the power to the motor? Also, following Alltraxe's troubleshooting directions, they recommend bypassing the F/R switch and running the motor directly off the controller to eliminate the controller and motor as the problem. I searched but couldn't find anywhere on this site where this is explained or recommended. Is it as easy as connecting the cables together that the bus bars in the F/R switch do?
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Old 09-25-2013, 06:57 PM   #2
pete959
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Default Re: Troubleshooting multiple carts with the same problem.

sounds like it might be the ITS
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Old 09-25-2013, 07:01 PM   #3
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Default Re: Troubleshooting multiple carts with the same problem.

Pete is right Ezgo ITS does not like to get wet. Have you tested the throttle signal at the controller?
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Old 09-25-2013, 07:53 PM   #4
TGJR
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Default Re: Troubleshooting multiple carts with the same problem.

Cart #1 shows ~9v on the black wire when the solenoid is activated and goes down to ~5.5v with the pedal fully depressed. Cart #2 shows ~17v on the black wire when the pedal is first pressed and it goes down to ~12v with the pedal fully depressed. The red wires on both carts show pack voltage when the solenoid is activated.

While reading the voltages of cart #1, the motor engaged 3 times in a row, stopped and then started working again a few minutes later. Only to stop working again. Nothing was moved or changed. It just likes to not work, work and go back to not working on its own. Will the ITS show obvious signs of water damage if I opened it up?
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Old 09-25-2013, 10:21 PM   #5
pete959
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Default Re: Troubleshooting multiple carts with the same problem.

yea my money is on its no they r sealed unit they wont show signs of anything
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Old 09-25-2013, 10:33 PM   #6
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Default Re: Troubleshooting multiple carts with the same problem.

I have seen them produce bad readings when wet. What controller was in what test result above? Wet peddle boxes and ITS can be dried out with a hairdryer...
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Old 09-25-2013, 11:11 PM   #7
TGJR
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Default Re: Troubleshooting multiple carts with the same problem.

Quote:
Originally Posted by scottyb View Post
I have seen them produce bad readings when wet. What controller was in what test result above? Wet peddle boxes and ITS can be dried out with a hairdryer...
Both carts have Alltrax AXE-4865 controllers.

I got into the ITS box in the cleaner of the two carts and it had some water in it. Not enough to cover the entire bottom of the box, but water nonetheless. I'll get into the dirty one tomorrow when I can get the mud out from around the rocker panel bolts.

What kind of voltages should I be seeing on the white wire inside the ITS box with the AXE-4865 controller?
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Old 09-26-2013, 04:38 AM   #8
JohnnieB
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Default Re: Troubleshooting multiple carts with the same problem.

Quote:
Originally Posted by TGJR View Post
Cart #1 shows ~9v on the black wire when the solenoid is activated and goes down to ~5.5v with the pedal fully depressed. Cart #2 shows ~17v on the black wire when the pedal is first pressed and it goes down to ~12v with the pedal fully depressed. The red wires on both carts show pack voltage when the solenoid is activated.

While reading the voltages of cart #1, the motor engaged 3 times in a row, stopped and then started working again a few minutes later. Only to stop working again. Nothing was moved or changed. It just likes to not work, work and go back to not working on its own. Will the ITS show obvious signs of water damage if I opened it up?
Quote:
Originally Posted by TGJR View Post
Both carts have Alltrax AXE-4865 controllers.

I got into the ITS box in the cleaner of the two carts and it had some water in it. Not enough to cover the entire bottom of the box, but water nonetheless. I'll get into the dirty one tomorrow when I can get the mud out from around the rocker panel bolts.

What kind of voltages should I be seeing on the white wire inside the ITS box with the AXE-4865 controller?
Based in the statement and question highlighted in Blue, it sounds like you are trying to check the ITS voltage on an Alltrax controller the same way the ITS voltage on a Curtis controller is checked. It isn't.

For Alltrax controllers, the ITS voltage is measured between the black and white wires.
The voltage between the black and the white wires should be 10V when the solenoid first clicks and 6V when pedal is on floor.

As for the question, the voltage between the black and white wires in the ITS box should be identical to the voltage between the black and white wires at the controller.
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Old 09-26-2013, 08:29 AM   #9
TGJR
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Default Re: Troubleshooting multiple carts with the same problem.

Quote:
Originally Posted by JohnnieB View Post
Based in the statement and question highlighted in Blue, it sounds like you are trying to check the ITS voltage on an Alltrax controller the same way the ITS voltage on a Curtis controller is checked. It isn't.

For Alltrax controllers, the ITS voltage is measured between the black and white wires.
The voltage between the black and the white wires should be 10V when the solenoid first clicks and 6V when pedal is on floor.

As for the question, the voltage between the black and white wires in the ITS box should be identical to the voltage between the black and white wires at the controller.
I checked the voltages between the white and black wires and they still show the same. Cart #1 moved for one pedal push and then stopped again and won't respond. The ITS voltages stayed within 9v-6v range whether it was moving or not. So can we rule out the ITS for that cart?

A little background on cart #2. This is the one that has been rode hard and put up wet. It has also seen it's fair share of fixes at the hands of people who know a lot more about planting fields and than working on electronics. I checked the ITS voltage between the black and white wires and it is still showing around 17v when the solenoid first clicks. Would a bad ITS show too much voltage? And when it does, how bad is that for the controller?
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Old 09-26-2013, 08:30 AM   #10
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Default Re: Troubleshooting multiple carts with the same problem.

Get a generator and your wife's hairdryer to camp ....
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