Question about Alltrax controller

[seanmcg]

Hey guys,

I finally, a year after buying it, finished wiring up the new Alltrax controller, HD F & R switch, solenoid, and new cables I bought from Scotty B. After connecting everything (I thought correctly), when I turn the key, I'm not getting any power to the controller (No LED). Can you guys tell me what might be some of the reasons why this isn't getting power? I've checked the battery pack, and it currently at 44.2V, still charging. I have no idea where to go from here.

Thanks,

Sean

[Sergio]

The Alltrax SR Controller KSI input is wired to the pedal micro-switch so the controller will not power up until you press the accelerator enough to "click" the micro-switch.

[seanmcg]

Ok, so I stood behind it and pushed the gas pedal with a broom handle. Every 5, or so, times I pushed it, I'd hear the click of the controller and the wheels would spin and the green light would blink 7 times, then go between green and red/amber. Any ideas why it is intermittently working? Also, I did notice that when I push the gas pedal, the electronic volt meter on the dash, shuts off completely, until I let off the pedal. The headlights don't shut off, just the volt gauge.

[Sergio]

Please disconnect the batteries and verify all the wiring before something is damaged.

You most likely have something wired wrong.

Check the diode on the Solenoid, the side with the band/stripe should be on the same small post as the positive activation wire.

Make sure there are no extra wires on the Solenoid big post that goes to the Controller B+, any smaller gauge wires on the big posts should go on the bug post that has the pack positive cable.

[seanmcg]

Ok, there is one smaller wire connected to the large post on the solenoid that goes to the B+ on the controller. I put this wire here because it's exactly where the wire was connected on the factory solenoid. Should this wire be moved to the smaller post with the other small red wire?

[Sergio]

Is that for the pre-charge resistor?

If so the pre-charger resistor is connected to both big posts, either because it has a ring connector on the lead or a small piece of wire soldered to the resistor lead.

If it is just a wire that goes into the harness then it should have never been on that side of the Solenoid and it should go on the big post with the battery cable.

[seanmcg]

Yes, the resistor is definitely connected across both big posts. Now I will move the one wire to the opposite big post which connects to the battery pack.

[seanmcg]

That did it. Thank you so much for your help and super fast responses!!! I really appreciate it.

[scottyb]

If I read this right the cart is on the charger now. Disconnect the charger and wait for the batteries to settle into normal voltage range to avoid conflicts with over voltage or charging lock out.

If it is a 48v cart at 44v you have a long way to go.
If a 36v cart at 44v they are close to done and should be let to settle to below 38-40 to avoid conflict

[seanmcg]

It is a 48V cart. That being said, should I leave it on the charger until it gets around 48-50V, before letting the batteries settle?