Cart vs cold temps

[Dondi12]

Placed 500 amp controller in my cart over the summer everything ran fine, still does as long as the temps don't fall below 55ish. When it gets cold my cart in reverse takes off at top speed. You really have to be prepared or a whiplash is in order. When going forward it bucks and bucks at slower speeds. It wants wide open or nothing. I know the cold is causing this, what can I do?

[Dondi12]

Sorry, 09', PDF, 500

[Dondi12]

Sorry, 09', ez go PDF, 500

[JohnnieB]

A '09 PDS maybe?

Is the 500A controller a an Alltrax DCX500?

If so, three problems come to mind.

1. ITS sensor
The potting compound shrinks and cracks as it ages and condensing humidity turns into moisture inside the ITS sensor and all sorts of strange things happen when the electronics inside the sensor gets wet.

2. Pedal microswitch.
An itty bitty spring is all that closes a microswitch's N.O. contacts and if the switch's mechanism is gummed up, the contacts don't close instantly in cooler weather, so the pedal is further down when the solenoid is energized.

Normally, the solenoid closes when the throttle signal is zero, but with the delay caused by the sluggish microswitch, it can be far greater than zero and the cart will jump.

3. In-line connector between pedal box and controller.
The wires for bot the pedal microswitch and the ITS sensor pass through this molex connector and dirty contacts in it have caused the abnormal behaviors mentioned above, plus others.

Also, dirty contacts in the PDS to DCX adapter plugs can cause strange things to happen.

Suggest cleaning all the control harness and adapter plugs. Disconnect them, spray with cleaner and reconnect while damp a couple times each.

If that doesn't cure the cart's ills, it is time to break out the DVM.

[scottyb]

Try parking the cart on blocks and testing the ITS signal first thing in the AM in reverse.

[Dondi12]

How do I test the ITS? What am I looking for?

[JohnnieB]

If it is in fact an Alltrax DCX500 controller, measure between pins 1 & 2 on top of the controller (or pins 3 & 4 on the four pin molex plug that plugs into the adapter).

You should measure 10V with the pedal up and 6V with pedal on floor.
If you have less than 10V the instant the solenoid clicks when you push the pedal, the cart will jump or jerk instead of taking off smoothly.

[cgtech]

Also, i assume you installed the required (but not included from alltrax) diode & resistor? The diode missing plays havoc on the throttle if it is missing.