Newbie needs help with controller wiring

BigMac!

This is going to be long but I want to give all the information I can so I can get the best advice. Thanks for any help you guys can provide.

My plan is to upgrade to 48 volt, 500amp controller, Heavy duty FnR, and 2g wires. And depending where I am with torque and speed after that have the motor rewound to add the final touch. Well after purchasing those components and Christmas I did not want to spend the money on batteries just yet.

So in my newbie misunderstanding I installed my 48 volt rated parts to my 36 volt battery pack using the supplied Altrax wiring diagram. Of course it didn't work due to the resistor not being rated correctly and allowing the controller to precharge. What happened was nothing when I turned on the key. Then depressing the pedal it would perform its blinking then go to solid green as it is supposed to but the wheels did not turn. And after a few seconds it would turn yellow. I did this test twice and realized something was not right and asked the provider of parts for advice. He informed me of my mistake and instructed me to use a 36 volt resistor and wire so I installed those and tried again. Only to have the same thing happen. I only did this test once because I was instructed not to experiment with my parts. And that I have already voided my warranty

From here I read alot of things on this website and reviewed my Altrax instuctions compared to the original wiring diagrams. While I am sure Altrax knows how to wire their products correctly I noticed that the stock wiring diagram and the Altrax diagram differ in the connections being made. So while I was originally a little confused, I am now completely confused and need some help.

I have taken pictures of what I think is everything so far and will provide those in my next post.

Thanks in advance!

BGW

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BigMac!

Here are some of the pics I have taken so far. If you guys need any other pics or angles I will take those also. And please forgive the cell phone quality. My digital camera's reduced shake feature isn't working and I can't hold it still enough to take a clear pic.

Here is a pic of the motor plate for reference.

And here is one of the connections on the motor.

A pic of the controller settings as provided written on the cover. ITS says 80% you just can't see it.

A pic of the FnR switch installed.

Pic of Altrax wiring diagram.

A pic of the controller wiring following Altrax diagram. The positive battery cable is not connected since I know something is wrong.

If you need a view of anything else just let me know.

scottyb

It should work.
Is the solenoid clicking when you try to go?

BigMac!

Yes it clicks, but nothing happens.

LostHusker

When you hear the click on the solenoid, what voltage are you getting on the left side of it? Use your Dvom measure with black lead on the neg batt pack and red lead on the left side of the solenoid.

scottyb

Mac, The stock diagram is for the stock 4 blade controller and the Diagram I sent with the cables is for the controller I sent you. Recheck every cable and be sure it is going to and from the connections according to my diagram... Solenoid clicking is a good sign. Did you say the green light was coming on on the controller?
If yes to the green light the problem may be in the F&R cables or the motor & controller cable routes. The F&R was bench tested before it left my shop as it has the upgraded HD switch cam installed.

BigMac!

Yes the green light comes on but not until I push the pedal and it goes through the blinking first. When should the controller activate and power up? As soon as the key is turned on?

I have gone through the wires at least 4 times today and they are correct to the Altrax diagram.

I also believe it is in the FnR somewhere. When checking continuity on the four outputs of the switch the top and bottom have continuity and the left and right have continuity. While in forward or reverse, is that correct?

I have performed the continuity checks on both micro switches and they are working correctly switching on and off as they should.

Where do I go from here?

scottyb

Your controller sequence is correct.
This is the correct continuity testing for the F&R.

Attached Images

Ezgo F&R cam test.jpg (95.7 KB, 10 views)

scottyb

The bolts on the F&R base look like they have not been removed recently. Did you install a complete F&R or just the HD switch cam? If switch cam only, try tightening nut B (1/2 turn at a time) as shown in the F&R directions Fig1

BigMac!

And all I needed was to tighten the nut more. This just proves to me that I really don't know anything when it comes to electrical. Thanks a ton!

I have a need for a couple more things so I will contact you soon.