98 EZGO Alltrax/Solenoid/SW202 Upgrade - Wiring not working

[Dmoney]

I think I need to check that the SW202 is clicking on reverse maybe

[Sergio]

It could be the angle of the picture, but it appears that the nut on the bottom L bracket under the S2 connection is not tighten at the Reversing Contactor.

Make sure all nuts are fully tightened.

[Dmoney]

I saw that and tightened it up -

[Sergio]

Since that bottom bracket connection is only used for Reverse I was hoping that was the issue.

[Dmoney]

I found this diagram on the Alltrax website and it is a little different than what I have wired up. I was thinking to take off everything from the SW202 and start fresh and follow this one. I can hear the soleniod and SW202 clicking on forward and reverse, so it must be the heavy current wires.

[Sergio]

That should not make any difference as both wiring diagrams are equivalent.

Is the picture You posted of the Reversing Contactor how is currently wired?

You have a notation that says "I switched these two wires", I just want to make sure it was done before the picture and not after.

Also, it appears You have washers between copper bars or copper bars and cable lugs, if that is the case they need to be removed, washer (if existing) should only go under the nut.

Please also verify the cables go to the motor posts indicated in the Reverse Contacor picture labels.

[Dmoney]

I switched the wires before the picture. The picture is the current setup. I will take the washers out and double-check everything. I need to remove the back seat again to get to everything.

thanks again

[Dmoney]

I took out the washers and double checked all the bolts.
WOW - everything seems to be working great.

Thanks for the help. I knew we were close and I can't thank you enough.

Guess I need to play with the computer throttle curve now.

Not sure exactly what I should set it to.
I was getting 19mph on flat paved ground just now and I think I have the settings turned down.

[Sergio]

That is great news and I apologize for the initial confusion based on my fat ginger mistake on the post referenced.

I just flagged those posts to the site admin asking for that typo to be corrected as not to cause further confusion.

I have a completely different system on my XCT 500 Sepex system with an MCOR throttle, but assuming the Alltrax default throttle linearization curves handle those differences so the Speed and Torque curves are throttle input device agnostic, meaning 25% pedal travel means 25% throttle input or horizontal axis on the curves and their algorithms relate the vertical axis for Speed and Torque settings to the proper PWM duty cycles, below is the speed and torque curves I use.

The idea is to allow the controller to initially develop torque without much forward speed change so it does not feel "jerky" during start up. I also allow more pedal travel during the start of the curve, 70% pedal travel translates to 40% of the max speed so there is more granular control and smooth operation at lower speeds.

Once the cart is going there is more speed change per given amount of pedal travel which gives you a better feeling of acceleration.

The curve is a little more gradual at the very end so it does not feel "jerky" with minor fluctuations of pedal at WOT.

I think You should set your throttle rate to 25% for a starting point and the forward speed to 100%.

Edit: Thanks to the site admins for already fixing that old post