foot switch wiring help for 48v upgrade

mathemagician44

So this weekend my project was to rewire the golf cart and upgrade from 36v to 48v, motor and all. Every wire, except at the foot switch, is new 12-, 10-, or 4-guage wiring done in accordance with the attached diagram that came with the Alltrax SR controller for pre 1994.5 EZ-GO. I abandoned all old wires cause someone had monekeyed with this thing in the past and I was unable to follow all of their wires/alterations - I was warned that this would be a problem when I bought it. I believe that everything is good thus far, except it has a constant beep from the reverse switch. I am sure this is something simple. I never really could find a diagram showing me where the short red wire from the horn that came on the F&R switch was supposed to go, and I must have assumed wrong with that short red wire that came on the new F&R wrong since it is getting constant power when the key is on.

Anyway, I cannot interpret the throttle foot switch part of this diagram. I have the wires from the controller to MS3 and MS4 and blank wires running from there down to the pedal just waiting to find their home. Speaking of, does it matter which side each wire goes into MS3 and MS4? Anyway, the diagram shows multiple wires at the foot switch, but not the number of wires I originally had and I am having a hard time figuring this out.

Cart originally had 5 wires at the pedal assembly: two wires running to the back of the pedal arm and a set of three thin wires (red, white, and black) coming out of a box on the drivers side of the pedal assembly. The two wires running to the passenger side of the pedal: one runs to the battery positive and the other to run switch and branches off to the key switch and the right terminal at J1. I cannot follow the where the three thin wires run.

I have two new wires that I ran to that area per the attached diagram that I don't know how to hook up: Branch coming from J4 and MS3 and J5 and Branch from MS3 and J5. If it is possible to follow this thread, can anyone help this foot switch - I have two new wires leading in without a home yet, and three potential homes for them??

Thanks All,
Matt

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yurtle

My series cart will sound the reverse beeper whether it's on or not. Not sure about Sepex, but on a series the beeper doesn't even need a controller to beep.

mathemagician44

I'm not sure if this makes it any more clear or not. The pink lines are wire branches that I have ran to the pedal area with no home. The two blue lines are two wires that I currently have hooked up to the back of the pedal because I think that is how it was or initially. They are new wires though thy I just tried the path with.

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mathemagician44

Anyone? What if I simplified the question - my foot pedal has 5 wires coming out if it, does anyone have a clearer diagram on where these wires should go?

JohnnieB

Looks like you have a older Marathon controller cart.

For starters, the microswitches on the Alltrax schematic are mislabeled. (I just noticed when I looked at it more closely)

MS-2 The run switch on the F/R assembly.
MS-4 Is a double microswitch on the F/R assembly. When reverse is selected, one of the switches sounds the beeper and the other puts controller into 1/2 speed.

MS-3 is the pedal switch on the Pot-Box assembly.

There ought to be six wires coming from the pot-box assembly.
2 to the throttle input to the controller.
2 to one of the MS-4 pair of switches.
2 from pedal switch, one from MS-2 and the other to the controller.

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mathemagician44

My foot switch definitely only has 5 wires. Anyone? I've got $2500 of brand new parts in this thing just waiting for the 10 more minutes of work to hook up the gas pedal to see how she runs. I have 6 nephews visiting for the weekend in two days that I know would love to play with it

scottyb

I don't know which thread to post in? Here goes

The 1987 pot had 3 functions. 6 wires.
Each function takes 2 wires.

1. on/off micro switch 48v in/48v out should trigger the solenoid and power the controller but you have to realize there is more than one way to skin this cat.
Having a diagram of the cart would help immensely = we could see what you have there.

2. 0-5k throttle signal. Should be easy to see which pair this is = they go all the way to the controller. Put your DVM on about 20,000 Ωs and plug it into the 2 leads while somebody or a stick presses the gas ... check it out.

3. Half speed reverse. When this pair are touching each other the 0-5k is reduced 50%. These wires go to the reverse micro switch on the F&R .

mathemagician44

I got her going forward Scotty! I only had 4 of the 5 hooked up though, I skipped the thin red one. That must be my reverse. I essentially pulled every wire out as far as possible to try to find any clues as to why I had this mysterious 5 wires. Turns out, there was a 6th wire tucked up behind the pedal that runs somewhere to the back of the cart. I have no idea where that wire was plugged into the pedal assembly, but it has to go somewhere, somehow. For now, I got feet to push me backwards. I am just glad to have met my wife's family deadline.

Once I get all these wires tightened up and a few inline fuses installed, I'll be in touch for new brakes. Thanks again for all your help. Though, you all may see another post from me at some point regarding power loss on hills, but I may find that issue simply by cleaning up the rest of my install.

mathemagician44

JohnnieB, that is also the name of a guy on one of my favorite radio talk shows. Anyway,
what did you mean when above you said:

"For starters, the microswitches on the Alltrax schematic are mislabeled. (I just noticed when I looked at it more closely)
MS-2 The run switch on the F/R assembly.
MS-4 Is a double microswitch on the F/R assembly. When reverse is selected, one of the switches sounds the beeper and the other puts controller into 1/2 speed."

When I took out the FnR this afternoon, I noticed that one of the two microswitches is always open in forward or reverse and closed anywhere in between. This microswitch is on the passenger side of the FnR and I wired this as the run switch. However, I noticed today that if I depress the run switch then reverse works, when it never has worked before. Once this happened, your post immediately ran through my head. I know my problem isn't as simple as the switches are wired backwards because I tried switching them and it didn't work correctly. Now I also remember a post with ScottieB mentioning which was on the passenger side that I am going to try to track down.

The ultimate problem I am trying to fix is why I have such little power all of a sudden with every part being only a month or two old. However, I never had reverse working prior to tonight and just never took the time to track it down.

mathemagician44

Here is a pic showing what would be the forward-facing side of my FnR, so the passenger switch is to the left.

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