Upgraded Contr / Solenoid / FR - HUGE SPARK! HELP

BigWes

Like the title says, I upgraded my cart with the Cartsunlimited package 485 (Alltrax SPM 48500 controller, HD Solenoid) and changed the cables to 2 ga cables, and upgraded to the HD FR switch.

I followed the directions on the packages to the T. I first changed out the FR Switch and Cables, then tested. Everything worked fine. Then I changed out the controller and Solenoid. Took pictures, made note of what number cable was on what post on the old controller and solenoid, made recordings telling me what went where. I reconnected them just like they were. When I went to reconnect the battery pack with the positive in the 1st battery everything still ok. Then I went to reconnect cable 7 from B- on controller to the neg terminal on the last battery and POW! It looked like I was trying to weld!!!

Any ideas on what could have happened? I double and triple checked everything. Any ideas on what I'm missing?

BGW

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scottyb

Something is not connected correctly. Can you post pics of all the wiring? And cabling so we can see what goes where....

BigWes

Here's what I have. If you need more, I can try to get some better ones.

Before
2014-08-08 21.07.38.jpg

After
2014-08-09 08.49.34.jpg

scottyb

The fuse and the solenoid look to be correct... triple check that Controller B- is connecting to battery main (-)

Where does the M- wire go?

BigWes

Just checked it B- on controller goes to neg terminal on battery pack.

Attachment 107872
Attachment 107871
Attachment 107870

M- on Controller goes to A2 on Motor

2014-08-09 09.19.01.jpg
2014-08-09 09.19.27.jpg
2014-08-09 09.19.36.jpg

BigWes

not sure what happened to the 1st set of pics. Here they are again. I think...
2014-08-09 09.18.00.jpg
2014-08-09 09.18.12.jpg
2014-08-09 09.18.21.jpg

scottyb

Probably something simple. leme think, can you recheck all the cable routes?

Attached Images

AXE-Series-Cable-install-diagram-#1-net.jpg (312.5 KB, 0 views)

BigWes

I'll go back and check them and write down what goes where.

scottyb

I see that pic of the cable end now ....... you have a dead short someplace. Check each cable -#1 thru 8 one at a time. Make sure no exposed ends are touching any metal other than the terminal they are attached to .

BigWes

Cable 1 - Rt side of Solenoid next to black wires, runs to + terminal on Battery pack.

Cable 2 - Left side of solenoid to B+ on controller

Cable 3 - B+ on controller to bottom of F/R switch

Cable 4 - Top of F/R switch to A1 on motor

Cable 5 - S1 on motor to Driver side connection on F/R switch

Cable 6 - connects A2on motor to M- on controller

Cable 7 - B- on Controller to Neg terminal on battery pack.

Cable 8 - Passender side F/R switch to S2 on motor

2 red wires from wiring harness connected to the controller go to the left side small terminal on solenoid.

Silver side of diode on left side connected to red wires.

1 Black wire from wiring harness to Rt side solenoid.
1 Independent black wire connects rt side of solenoid to B- on the controller.


Are there any connections I'm missing or that I didn't note here?