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Old 12-01-2018, 09:38 AM   #1
SEHunter
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Default Lost forward travel with reversing contactor

99 CC DS, Alltrax SR48600, ScottyB reversing contactor

Had just pulled up to my basement in the yard and hopped out to grab something...hopped back in the cart seconds later, backed up and flipped the rocker switch back to the left to head back to the barn, and the cart wouldn’t go forward. Cycled the switch several times...reverse good but no forward.

I could still hear and feel the loud click of the reversing contactor after pressing the pedal with the rocker switch in fwd. I verified I indeed was hearing the reversing contactor and not just the primary solenoid alone. With the rocker in neutral, only the primary solenoid pulls in and it’s much quieter than when combinind with the reversing contactor once the switch is pressed in either direction for a travel request. To me that tells me the rocker switch and reversing contactor are doing their jobs in sending current to the controller...which led me to assume the SR controller. Before business hours ran out on me yesterday, ScottyB responded quickly to a late email to tell me on a Series cart, the controller does the same thing in either direction so if I’m losing only one direction, it shouldn’t be a controller issue. The green LED sequence on the SR controller appears the same with the pedal pressed when in either fwd or reverse. I do not have any red LEDs when the pedal is pressed to go fwd even when the cart isn’t moving.
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Old 12-01-2018, 09:49 AM   #2
NoleFan4Ever
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Default Re: Lost forward travel with reversing contactor

Definitely sounds like something between the RC and/or connections. Have you traced the power out with your Volt Meter yet? Power in one direction verified out, then when changing directions.
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Old 12-01-2018, 10:29 AM   #3
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Default Re: Lost forward travel with reversing contactor

Make sure you can hear the "bang" sound from the contactor both when it engages and disengages while You are on Reverse.

They could be sticking, tap the contactor with a rubber mallet or a wood handle and try forward again.
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Old 12-01-2018, 11:08 AM   #4
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Default Re: Lost forward travel with reversing contactor

Things got goofy this morning. Regrouped this morning, pulled out the rocker to swap the fwd and reverse wires that go to the RC coils to see if the symptoms changed to reverse and restore fwd. All that did was change the direction the switch is to be pressed for direction. Still no fwd. I swapped the wires back and popped the switch back in. All of a sudden fwd worked. Verified good wiring and connections. Wish I’d have checked RC output as you advised before it mysteriously started to work.

I expect it to reoccur. Based on the initial symptoms, the only thing I can think is although the RC engages with a fwd travel request, there must be something up with the contact tip fully closing? I don’t think it’s likely since it’s so loud but the symptoms alone seem to rule out all other components according to theory of operation. Maybe I’m missing something.
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Old 12-01-2018, 11:16 AM   #5
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Default Re: Lost forward travel with reversing contactor

Quote:
Originally Posted by Sergio View Post
Make sure you can hear the "bang" sound from the contactor both when it engages and disengages while You are on Reverse.

They could be sticking, tap the contactor with a rubber mallet or a wood handle and try forward again.
Good idea, that didn’t cross my mind.
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Old 12-01-2018, 11:26 AM   #6
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Default Re: Lost forward travel with reversing contactor

I have always found that my very closest fix when troubleshooting electrical issues has always been with my DVM. It proves or disproves most any thought or theory....
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Old 12-01-2018, 11:54 AM   #7
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Default Re: Lost forward travel with reversing contactor

True, I was impatient and went straight to yanking wires and swapping stuff. Will definitely slow down and grab the meter if it happens again. Related question for your guys opinion...

The way I have the RC coils wired for the throttle signal, the RC engages every time I press the accelerator pedal, so every time I depress and release the accelerator, the RC pulls in/out, in/out, etc. Could this be over working the contactor? I’ve wondered if I should use the rocker switch to energize the RC coil instead of the accelerator pedal?
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Old 12-01-2018, 01:14 PM   #8
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Default Re: Lost forward travel with reversing contactor

Since You heard the Contactors clicking, likely was not a loose cable since you could easily spot.

If the Reverse Contactor is not releasing the N/O contact, the cart will not move even if the Forward Contactor closes.

As long as the Contactor is not mounted with the posts pointing down, a welded contact situation could describe the symptoms.

Those Contactor coils get pretty hot if you forget them ON, so have it come ON with the foot pedal is a good idea.
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Old 12-01-2018, 01:17 PM   #9
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Default Re: Lost forward travel with reversing contactor

Also the mechanical lifespan of the RC is about 200,000 times that would take a very long time to wear out.
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Old 12-01-2018, 02:19 PM   #10
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Default Re: Lost forward travel with reversing contactor

Quote:
Originally Posted by Sergio View Post
Since You heard the Contactors clicking, likely was not a loose cable since you could easily spot.

If the Reverse Contactor is not releasing the N/O contact, the cart will not move even if the Forward Contactor closes.

As long as the Contactor is not mounted with the posts pointing down, a welded contact situation could describe the symptoms.

Those Contactor coils get pretty hot if you forget them ON, so have it come ON with the foot pedal is a good idea.
Ok thanks for confirmation
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