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Old 06-08-2013, 06:38 AM   #1
timbo73
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Default Intermittent Controller Issues - AXE4855

Good Morning Guys,

Last night while coming to the bottom of the hill I lost power. Throughout the night and into the morning I've been reading up on these threads. First thing this morning after having done nothing to the cart it worked for about 20 feet then failed again. I came across the post pasted below. I ran both tests multiple times. Every now and then the cart power works then fails almost immediately. Results of the tests are shown below next to the post's details.

ITS voltage for an AXE 4844 controller is measured between black and white wires.
Should be 10V at solenoid click and 6V pedal down. - This works every time, when the cart is working and when it is not.

Measure battery pack voltage.
Then place DVM test leads between B- and M- terminals on controller.
Should read FULL battery pack voltage when solenoid first clicks. - This works every time, when the cart is working and when it is not.

If it doesn't read FULL battery pack voltage, there is an issue in the high current circuit that is external to the controller.

If you have FULL battery pack voltage between B- and M-, press pedal slowly to floor.
Voltage should smoothly decrease to Zero, or very near Zero. - When the cart is working this performs as it should. When it is not working the voltage does not decrease.

If it doesn't, either the controller or ITS is bad. (ITS test is give in the beginning of this post)

I purchased the Controller in February 2012 from Carts Unlimited.

Any additional help or warranty information you can pass along? Next weekend I have two full days of visitors coming out to the lake and I'd rather not haul everyone on my back around the campground.

Thanks in advance!
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Old 06-08-2013, 08:42 AM   #2
scottyb
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Default Re: Intermittent Controller Issues - AXE4855

Alltrax has a 2 year factory warranty.

Was the solenoid clicking when the cart will not go?
Does the solenoid click when the cart motion stops?

Not reading a voltage drop between B- and M- without the solenoid pulled in (click) is not a valid fault. The solenoid MUST pull in (Click) for this test.

Hope this helps
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Old 06-08-2013, 08:52 AM   #3
timbo73
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Default Re: Intermittent Controller Issues - AXE4855

Hi Scotty,

The solenoid clicks every time.

I continue to leave it and come back and sometimes the cart will start again and sometimes it doesn't. I'm finding it works well on stands then when I attempt to drive it it stops.

Thanks for any additional assistance.
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Old 06-09-2013, 06:09 AM   #4
yurtle
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Default Re: Intermittent Controller Issues - AXE4855

My '98 TXT Series cart has a molex plug that connects the ITS and throttle microswitch to the wiring harness. It's located near the FNR. It occasionally needs wiggling. I need to replace it, but just haven't gotten around to it. May want to check all of the plugs.
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Old 06-10-2013, 04:48 AM   #5
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Default Re: Intermittent Controller Issues - AXE4855

Well guys the mystery still continues. The cart ran well yesterday without issue but feel like it is a ticking time bomb.
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Old 06-10-2013, 08:56 AM   #6
scottyb
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Default Re: Intermittent Controller Issues - AXE4855

Intermittent problems are hard to find. Carry the testing meter with you and resign yourself to working on solving the mystery whenever (and wherever) the dang thing stops.



In my experience, the cart will run great as long as the tools to fix it are in it, LOL
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Old 06-10-2013, 09:10 AM   #7
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Default Re: Intermittent Controller Issues - AXE4855

As always, great advice Scotty. In addition, I now carry a tow strap on board.
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Old 06-13-2013, 11:40 AM   #8
1joe reilly
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Default Re: Intermittent Controller Issues - AXE4855

Hi Tim
Had similiar problem. Cart dead. Solenoid always clicked but no move.
Replaced the solenoid now everthing dead-no solenoid click no reverse warning.
Still troubleshooting problem,will let you know when fixed. Could be controller problem. Any help appreciated.
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Old 06-13-2013, 11:54 AM   #9
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Default Re: Intermittent Controller Issues - AXE4855

I still have yet to find the root cause of the symptoms I am having. I will definitely post my findings if I do.
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Old 06-13-2013, 05:57 PM   #10
chloe
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Default Re: Intermittent Controller Issues - AXE4855

Yurtle suggested you check all the plugs. Now I'm going to suggest you clean them and add a spot of dielectric grease. Your problem sounds too much like poor contact and that very often is due to corrosion.
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