Finishing up a controller, solenoid, and FNR upgrade

[ontheroad247]

A have 1993 36 volt marathon that I am working on upgrading the controller, solenoid, and F/R switch. The new controller is the Alltrax SR48500.

If it is possible, I could use some advice. I’ll try to explain what I have.

1. With everything connected like the schematics show, the cart wants to move forward when set on reverse.
2. With the f/r knob in forward it doesn’t do anything. The light on the controller indicates Pre-Charge Failure.
3. There is a wire coming from the pot that originally went to “1” terminal on the original controller. Is this supposed to go anywhere now?

What direction do I need to go to figure out what I have wrong?

[scottyb]

See the diagram on page 15 of the owners manual. The pot switch is marked foot switch. The wire you asked about goes to the solenoid small +.

If the direction is switched swap the 2 F&R cables at the 3 and 9 o'clock positions.


"pre-charge failure" is usually solenoid failure to engage or activate unless the precharge resistor is actually not installed

[ontheroad247]

I switched 9 and 3 around and now the the solenoid doesn't click in forward and it gives a Battery Over Voltage code in reverse.

[ontheroad247]

The picture below shows the wire I was asking about. The red wire goes to the MS4 switch like the schematic shows. The orange goes to the + side of the solenoid. The blue doesn't go anywhere right now but it did go to "1" on the old controller.

[ontheroad247]

Update: I found another schematic labeling the motor studs in a straight line. I had to switch S1 and A2 around. This made the wheels go forward and reverse accordingly while on the jack stands. But when I set it on the ground, it won't go forward. It moves in reverse just fine, but won't move going forward. It is not setting off any codes on the controller. Still could use some suggestions.