Alltrax DCX500 diagnostic issue

rabbitreborn · 09-18-2010, 04:50 PM

I just looked at the pics again......

You put the jumper in the wrong place...... That is why you are getting sparks.... You have to place the jumper between the LARGE posts not the small posts...... Hopefully you didn't blow anything by jumpering the small posts.

scrunner · 09-18-2010, 04:54 PM

are you asking if i've been having sparks? i haven't, till i just tried to reconnect the b+. to recap: i removed the diode, left the blue and yellow attached where they were, since the cart was working fine like that before, and jumped the two LARGE posts this time with an old 6ga cable. went to connect the b+ and arc welded a little, didn't leave it on there, obviously. yes, i am putting it in tow mode. getting a little frustrated now, its a good afternoon to be riding!

scrunner · 09-18-2010, 04:56 PM

The whole sparking thing with this cart bothers me but, it ran for hours?

ran about 3 miles last night and long enough this morning to pull it into the back yard.

scrunner · 09-18-2010, 05:15 PM

also, if anyone has a sec, could you confirm that 'TOW' is towards the red and orange wires on the switch?

rabbitreborn · 09-18-2010, 06:03 PM

Quote:

Originally Posted by scrunner

are you asking if i've been having sparks? i haven't, till i just tried to reconnect the b+. to recap: i removed the diode, left the blue and yellow attached where they were, since the cart was working fine like that before, and jumped the two LARGE posts this time with an old 6ga cable. went to connect the b+ and arc welded a little, didn't leave it on there, obviously. yes, i am putting it in tow mode. getting a little frustrated now, its a good afternoon to be riding!

I have never seen a sepex system yet that didn't spark a little when you connect the B+ wire to the battery pack regardless of the switch being in tow or run. when you say arc welded, was it getting hot to the touch? I can't confirm the tow switch direction but a quick check with a multimeter set for continuity should confirm which direction it should be in.

sorry for the delayed response but I was doing some yard work

scrunner · 09-18-2010, 06:10 PM

no problem, thanks for all of your help so far.

no, it was just sparked and blackened the battery nut when i tried to reconnect the b+, mine normally doesn't spark, when i had the jumper on the two big posts of the solenoid. i took the jumper back off, put the diode back on and hooked up the batt again with no spark; but the light started flashing...

something that's bothering me about all this is that the controller always seems to have power regardless of key switch position or run/tow switch position. as soon as i get the batt reconnected the light starts flashing green.

rabbitreborn · 09-18-2010, 07:05 PM

ok on the small posts for the solenoid, one side should have JUST the blue wire on it. The other side should have the white and yellow wire from the keyswitch, the red wire from the pedal box and the yellow wire from the controller attached to it. Is the wiring correct?

scrunner · 09-18-2010, 07:20 PM

no, that's not what i have. i don't have a white wire. just one of each of the following: red, blue and yellow. i had red going to the large solenoid post on the controller side, and the yellow and blue on opposite small posts with the diode.

in your wiring does it matter which side the blue and yellow wires are on (and i guess the red wire would be with the yellow)?

rabbitreborn · 09-18-2010, 07:29 PM

I was going by the wiring diagram. the power wiring from/to the keyswitch is what color? the diagram says it should be a yellow and a white/yellow with the yellow coming from the direction selector and the whit/yellow coming from the solenoid (attached to the same small post as the yellow and the red wire).

No, it shouldn't make a difference regarding the 2 small posts as long as the banded side of the diode is towards the post that the yellow,red and white/yellow wires are mounted to.

scottyb · 09-18-2010, 07:32 PM

I am also in & out but just to answer your question about the polarity of the solenoid activation circuit..... No the small posts are not polarity sensitive. YES the diode between them is polarity sensitive. So while switching the blue and yellow wires on the small terminals makes no difference at all to the solenoid ... it makes a world of difference to the diode which is marked with a silver band on one end and that silver banded end must be on the same side as the positive wire (yellow). Hope this clears up my comment earlier about having the diode backwards...... remove the diode for a moment and put it in your pocket. It may have a problem.

09-18-2010, 04:50 PM	#21
rabbitreborn Gone Wild Join Date: Jun 2010 Location: Central Florida Posts: 2,757	Re: Alltrax DCX500 diagnostic issue I just looked at the pics again...... You put the jumper in the wrong place...... That is why you are getting sparks.... You have to place the jumper between the LARGE posts not the small posts...... Hopefully you didn't blow anything by jumpering the small posts.

09-18-2010, 04:54 PM	#22
scrunner Gone Wild Join Date: Oct 2009 Location: Greenville, SC Posts: 152	Re: Alltrax DCX500 diagnostic issue are you asking if i've been having sparks? i haven't, till i just tried to reconnect the b+. to recap: i removed the diode, left the blue and yellow attached where they were, since the cart was working fine like that before, and jumped the two LARGE posts this time with an old 6ga cable. went to connect the b+ and arc welded a little, didn't leave it on there, obviously. yes, i am putting it in tow mode. getting a little frustrated now, its a good afternoon to be riding!

09-18-2010, 04:56 PM	#23
scrunner Gone Wild Join Date: Oct 2009 Location: Greenville, SC Posts: 152	Re: Alltrax DCX500 diagnostic issue The whole sparking thing with this cart bothers me but, it ran for hours? ran about 3 miles last night and long enough this morning to pull it into the back yard.

09-18-2010, 05:15 PM	#24
scrunner Gone Wild Join Date: Oct 2009 Location: Greenville, SC Posts: 152	Re: Alltrax DCX500 diagnostic issue also, if anyone has a sec, could you confirm that 'TOW' is towards the red and orange wires on the switch?

09-18-2010, 06:10 PM	#26
scrunner Gone Wild Join Date: Oct 2009 Location: Greenville, SC Posts: 152	Re: Alltrax DCX500 diagnostic issue no problem, thanks for all of your help so far. no, it was just sparked and blackened the battery nut when i tried to reconnect the b+, mine normally doesn't spark, when i had the jumper on the two big posts of the solenoid. i took the jumper back off, put the diode back on and hooked up the batt again with no spark; but the light started flashing... something that's bothering me about all this is that the controller always seems to have power regardless of key switch position or run/tow switch position. as soon as i get the batt reconnected the light starts flashing green.

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09-18-2010, 07:05 PM	#27
rabbitreborn Gone Wild Join Date: Jun 2010 Location: Central Florida Posts: 2,757	Re: Alltrax DCX500 diagnostic issue ok on the small posts for the solenoid, one side should have JUST the blue wire on it. The other side should have the white and yellow wire from the keyswitch, the red wire from the pedal box and the yellow wire from the controller attached to it. Is the wiring correct?

09-18-2010, 07:20 PM	#28
scrunner Gone Wild Join Date: Oct 2009 Location: Greenville, SC Posts: 152	Re: Alltrax DCX500 diagnostic issue no, that's not what i have. i don't have a white wire. just one of each of the following: red, blue and yellow. i had red going to the large solenoid post on the controller side, and the yellow and blue on opposite small posts with the diode. in your wiring does it matter which side the blue and yellow wires are on (and i guess the red wire would be with the yellow)?

09-18-2010, 07:29 PM	#29
rabbitreborn Gone Wild Join Date: Jun 2010 Location: Central Florida Posts: 2,757	Re: Alltrax DCX500 diagnostic issue I was going by the wiring diagram. the power wiring from/to the keyswitch is what color? the diagram says it should be a yellow and a white/yellow with the yellow coming from the direction selector and the whit/yellow coming from the solenoid (attached to the same small post as the yellow and the red wire). No, it shouldn't make a difference regarding the 2 small posts as long as the banded side of the diode is towards the post that the yellow,red and white/yellow wires are mounted to.

09-18-2010, 07:32 PM	#30
scottyb Happy Carting Join Date: Dec 2007 Location: Southern California Posts: 73,419	Re: Alltrax DCX500 diagnostic issue I am also in & out but just to answer your question about the polarity of the solenoid activation circuit..... No the small posts are not polarity sensitive. YES the diode between them is polarity sensitive. So while switching the blue and yellow wires on the small terminals makes no difference at all to the solenoid ... it makes a world of difference to the diode which is marked with a silver band on one end and that silver banded end must be on the same side as the positive wire (yellow). Hope this clears up my comment earlier about having the diode backwards...... remove the diode for a moment and put it in your pocket. It may have a problem.

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