36v DCS issues

[fabricator]

Evening everyone. I bought a 36v dcs cart with a fried controller. So I bought a
Alltrax XCT48400DCS controller and HD solenoid. Wired everything up and
Powered it up and got 4 flashes and then solid green. Problem occurs when I press pedal. Wheels barely turn. The controller gives the low voltage code. 1 flash green and then 2 red flashes. Battery pack has 38.2v. When I press pedal battery pack drops to37.8v. So after much frustration and head scratching, I put in another set of batteries from a running cart. I continue to get the same results above. Low voltage code. 1 green and 2 red flashes. Going to try to post some pictures.

[fabricator]

Any help is appreciated

[scottyb]

Did the cart run before the upgrade?

[scottyb]

Are you sure the 2 small red wires on the solenoid big post is on the right post? The Alltrax diagram shows one small wire on the battery side of the solenoid big posts....looks like it might be on the controller side? Hard to see......

[fabricator]

I did not have the cart running before the upgrade

Im not at all sure about the 2 small red wires being correct? For clarification. The 4 ga black wire is going to the battery +. The red 4 ga wire I had to make longer and it lands on the B+ at the controller. trying to post better Pictures

[fabricator]

Pictures attached

[Raystar57]

Fabricator, the solenoid is not connected correctly.

First the two red wires are correct as they are going to the pack + via the black cable. See red block.

The issue is you have the yellow/white wire on the small - terminal on the solenoid.
There should only be the blue (which is correct) and the BLACK side of a small diode "1N5408" on those - terminals. See orange block
They are common in the solenoid and both terminals are the same for easy hookup.

There are actually three wires on the small + terminals. See blue block.
White/Yellow, Red and Yellow (which you have correct, just missing the White/Yellow).
There is also the small diode (silver band) connection there also.

Also note the TWO diode specs (purple block), one for coil voltage suppression and the larger one (6A6 - 6A 600V) for Regen.
I see that larger Regen one (#5) but I don't see the small one (#1) across the small terminals in your setup.
See green block.

Check those diodes and correct that wire error and hopefully you will be good to go.

This should be correct but if not the master experts here will let us know.

[fabricator]

Raystar. You are correct. I switched the yellow white wire to land on the positive side. Solinoid works as it should now. Get green light. And cart most importantly runs as it should. I see your concerns about the diode in the diagram. The solinoid came with the diode that lands on the big lugs at the solinoid in pic attached. It also came with a fuse that I have in line going to the negative side of the battery pack. Your saying that there should be another # 1 in diagram going between the small terminals on solinoid. Where's a local place to get one of these. Amazon sell these? Thx Raystar you have been a great help and I appreciate it.
Listen guys. I would like to give a special thanks to Scottyb at cartsunlimited for all the help and support. He has taken alot of time after hours. And weekends sharing his knowledge and skills with this and other issues I've had. Thx Scotty

[scottyb]

This is a XCT control version 2 - it has the suppression diode function covered. You can put one on for your piece of mind. It will be redundant and you better get it on their going the right direction or it will damage other components in the cart.

[fabricator]

Scotty. Your saying Version 2 doesn't need it. So im good to go with out it correct?