Intermittent Operation

[LBrown867]

Bump...My time right now is limited so I am going to try to work on it this weekend if there is any more troubleshooting to do before replacing something...Thank you in advance ScottyB and JohnnieB!!

[scottyb]

With the fan coming on and no movement. You have one of the high amperage cables on the wrong terminal. Triple double check the high amp cable routes. The fan coming on with the go pedal is the giveaway.

[LBrown867]

One of the high amperage cables going to the reversing contactor?

Originally Posted by scottyb

With the fan coming on and no movement. You have one of the high amperage cables on the wrong terminal. Triple double check the high amp cable routes. The fan coming on with the go pedal is the giveaway.

[scottyb]

Originally Posted by LBrown867

One of the high amperage cables going to the reversing contactor?

....... or the controller? I'll just bet the fan is coming on because there is a high amp cable on the wrong terminal SOMEWHERE.

[Alltrax Tech]

I will wait for a response about whether the controller is wired properly because scottyb is on the right track.

[LBrown867]

Scotty And Alltrax tech. I have followed the attached wiring diagram again to ensure all high amp cables are in the right place and I'm not seeing any errors. I have also attached a second picture of the wires coming to the reversing contactor. When looking at the picture I took of my installation, from left to right: cable #8 which is going to the motor, cable #4 which is also going to the motor, cable #6 which is going to the motor, and last but not least cable #3 which is going to the B+ terminal on the controller.

As I've mentioned, the cart used to operate fine minus the fan kicking on for a second every time you hit the pedal. I haven't touched it in a week or so and I just came out here to get this info for you guys and I turned the key on, put it in reverse, and it went, put it in forward and it went. When I pushed the pedal to engage forward motion, I intentionally never let out of it far enough to let it disengage the contactor and it continued to operate but as soon as I let out of it completely, it no longer worked. I'm sure if I give it awhile and try again again, it will work. I hope this helps. Thank you guys so much for the IMG_0883.jpg
IMG_0882.jpg

Originally Posted by scottyb

....... or the controller? I'll just bet the fan is coming on because there is a high amp cable on the wrong terminal SOMEWHERE.

[Alltrax Tech]

when you let off the pedal fully and go to press it again and the cart doesn't work. What does the light do on the controller? Does the solenoid click?

[scottyb]

I have received and tested the solenoids which both passed.
We have another great technician consulting now to see if we can solve this.

One thing I keep reading is the cart is intermittently working.
The controller is giving the correct LED status codes.
The Solenoid is quite functional although this picture taken on my workbench shows something burnt and corrosion on both small posts.
I have seen in one case where the local moisture was so high it bridged the small to large terminal creating a short.
Customer replaced that solenoid and had no more issues I know of?