Alltrax DCX500 diagnostic issue

[scrunner]

when i opened up the seat to plug in my programming cable just a minute ago, the green light was flashing 4 times, pausing, then repeating constantly. key off, selector in neutral. the resistor (i think that is what it is - the white bar that goes between the small posts of the solenoid) was really hot to the touch. when i switched the key on and put it in fwd, the controller flashed 4 times green, ITS, then flashed 7 for undervoltage. checking the current from the positive batter post to the negative on the controller was only 30.7; pack voltage is up around 38.8.

anyone have any ideas what i should check?

ps - i was getting an undervoltage code yesterday right after i installed it, but i reversed the purple and yellow wires and it cleared it up. rode all night, really fast!

appreciate any help, its time for a beer

[rabbitreborn]

You changed the controller but did you change the solenoid as well? Did you replace the diode (the piece you mention that is getting real hot)?

From what you are describing it sounds like a solenoid issue. you can always try placing a large jumper between the 2 large posts of the solenoid and see if it is back to working properly.

[scrunner]

yep, put all new solenoid, diode and resistor. what will putting the jumper in do? should i get the back wheels off the ground first, or just put my beer down and hold on?

ps - thanks for the quick reply

[rabbitreborn]

installing the jumper basically just bypasses the solenoid. The cart should run as normal, but for safety sake I would lift the rear wheels off the ground first.

Since everything is new, it is possible you have a bad diode on there causing the issue, If the jumper works, try removing the diode and running it (minus the jumper), if it works, replace the diode (or just leave it off completely)

[scrunner]

ok cool. just to be clear - the diode is a little black cylinder that has to be attached in a certain orientation, and the resistor can go either way (haha)? the resistor looks like a rectangular piece of chalk. do i have that right?
so, you are saying, put the jumper on, and if it works fine, then just remove the diode (little black cylinder) and replace it later. right? sorry for all the questions!!

[rabbitreborn]

yes to everything you just posted.

[scrunner]

you da man. i'll go give it a shot.

[scottyb]

Might be you smoked the diode when you connected it backwards?

Rabbit, how's the marathon? Pot fix it?

[scrunner]

crap. didn't work. i didn't put the diode on backwards, just the yellow and blue wires.

as soon as i reconnect the positive cable, the controller starts flashing green (even with the key off in neutral), and the resistor gets hot... wth

pics coming, if they will ever upload...

[scrunner]