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Old 03-16-2018, 01:40 PM   #1
DennisWitt
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Default Altrex 48400 reverse but no forward

I’m looking for a little insight from the experts....
The cart has the following:
36 V lithium pack.
Altrax sr48400 controller.
Heavy duty forward reverse contactor.

Everything seem to be working perfectly for about the last 90 days and then I would occasionally have a situation where the cart would not move forward. If I would wait 60 or 90 seconds with the key switch off the cart with then resume normal forward operation. This slowly devolved to A situation where if I drive Forward at full throttle for half a mile or so I would seem to lose power temporarily but after a short rest everything was normal again. Eventually got to a situation where the car will only go in reverse.
No errors showing on the Alltrex.
Does anyone have any thoughts?
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Old 03-16-2018, 03:33 PM   #2
DennisWitt
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Default Re: Altrex 48400 reverse but no forward

Quote:
Originally Posted by DennisWitt View Post
I’m looking for a little insight from the experts....
The cart has the following:
36 V lithium pack.
Altrax sr48400 controller.
Heavy duty forward reverse contactor.

Everything seem to be working perfectly for about the last 90 days and then I would occasionally have a situation where the cart would not move forward. If I would wait 60 or 90 seconds with the key switch off the cart with then resume normal forward operation. This slowly devolved to A situation where if I drive Forward at full throttle for half a mile or so I would seem to lose power temporarily but after a short rest everything was normal again. Eventually got to a situation where the car will only go in reverse.
No errors showing on the Alltrex.
Does anyone have any thoughts?




This is the diagram I used to wire things. Is this correct?
Also, can anyone tell me what resistance is should see on the diodes on the f/r contractor?
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Old 03-16-2018, 05:11 PM   #3
scottyb
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Default Re: Altrex 48400 reverse but no forward

Are you asking if the install instruction is correct?

It sounds like you had it hooked up right or it would not have worked at all let alone for 90 days. The wild card in this install is the lithium battery pack and BMS we know nothing about. Alltrax tech might be able to help or you can save and post some monitor files so we can see if we see anything glaringly wrong.
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Old 03-16-2018, 06:41 PM   #4
DennisWitt
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Default Re: Altrex 48400 reverse but no forward

Scotty, i really don’t think it is the alltrax. And the lithium pack is fine...that is one area I know fairly well. I’m thinking something with the f/r contractor. What resistance should I see on the diode for that contractor? Or, can you coach me on how to test?
I took the f/r contractor apart and had much trouble reassembling so I may also have created an issue there. May have to buy a new contractor. ...
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Old 03-17-2018, 08:03 AM   #5
Sergio
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Default Re: Altrex 48400 reverse but no forward

You can use a Multi-Meter set to resistance to check the diode once it is disconnected from the Contactor.

You should get "infinite resistance" or 0L in one direction and some resistance (100Ω to 1,000,000Ω depending on the meter) in the other direction.

If Your meter has a "diode check" that is a better option, You should get 0.5v to 0.8v in one direction and 0v with the probes reversed.

When You had the Contractor apart, did You check if the studs contact surfaces were in good shape?

The one potential issue I see is that circuit allows You to change directions without lifting Your foot from the accelerator pedal.

You (or anyone else driving your cart) should never do that or the Contactor would open/close with current going through it and potentially damage/pit/burn the contacts.
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Old 03-17-2018, 08:55 AM   #6
scottyb
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Default Re: Altrex 48400 reverse but no forward

Intermittent problems can be hard to find. Is the contactor clicking in both directions when the cart will not go?
Here is a test for the reversing contactor.
Attached Images
File Type: jpg test.jpg (83.3 KB, 0 views)
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Old 03-17-2018, 09:00 AM   #7
DennisWitt
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Default Re: Altrex 48400 reverse but no forward

Quote:
Originally Posted by scottyb View Post
Intermittent problems can be hard to find. Is the contactor clicking in both directions when the cart will not go?
Here is a test for the reversing contactor.


Thank you Scotty and Sergio ! I’ll be testing today.
This group is amazing. Thanks for all the help.
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Old 03-17-2018, 09:42 AM   #8
DennisWitt
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Default Re: Altrex 48400 reverse but no forward

Quote:
Originally Posted by Sergio View Post
You can use a Multi-Meter set to resistance to check the diode once it is disconnected from the Contactor.



You should get "infinite resistance" or 0L in one direction and some resistance (100Ω to 1,000,000Ω depending on the meter) in the other direction.



If Your meter has a "diode check" that is a better option, You should get 0.5v to 0.8v in one direction and 0v with the probes reversed.



When You had the Contractor apart, did You check if the studs contact surfaces were in good shape?



The one potential issue I see is that circuit allows You to change directions without lifting Your foot from the accelerator pedal.



You (or anyone else driving your cart) should never do that or the Contactor would open/close with current going through it and potentially damage/pit/burn the contacts.


Found that my meter has diode test. Both diodes check good.
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Old 03-17-2018, 09:45 AM   #9
DennisWitt
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Default Re: Altrex 48400 reverse but no forward

Quote:
Originally Posted by scottyb View Post
Intermittent problems can be hard to find. Is the contactor clicking in both directions when the cart will not go?
Here is a test for the reversing contactor.


Both sides of the contractor tested good. I really thought the contractor would test bad...since I had taken it apart to check for piting in contractors.
Still looking for an answer.
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Old 03-17-2018, 12:30 PM   #10
Sergio
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Default Re: Altrex 48400 reverse but no forward

There are 2 possible Contactor failures that can cause the cart to not go on Forward:
1) The N.O. (top) contact of the Forward Solenoid is not making contact.
2) The N.C. (bottom) contact of the Reverse Solenoid is not making Contact.

ScottyB test was only for the Top Contacts, You also need to make sure the Bottom contacts are closing when tha side of the Contactor is OFF.

If You already re-connected all of the cables, You may be able to at least verify the "Clicks" as the Contactors close the top and bottom contacts as power is applied and removed.

If Your cart is wired exactly like the diagram you showed:
Starting with the FNR in Neutral, press the pedal until you hear the Main solenoid "Click" but not too far.

Try to keep the pedal still so the Main solenoid stays closed for the entire test.

Now move the FNR to Forward and listen for the loud "clunk" of the forward Solenoid when it Closes.

Move the FNR to Neutral and listen to the Forward solenoid make another "clunk" as it releases the top contacts and closes the bottom contacts.

Do that a few times to make sure You can hear both events.
Now to the same test but between Neutral and Reverse.
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