Power Surging?

[Sergio]

It may not make much difference most of the time, but the original circuit activates the controller and solenoid simultaneously, so the controller will be ready to send power to the motor proportionally to its throttle map.

The HPD fault indicates the controller senses too much throttle at the time the MCOR micro-switch closes.

If We activate the controller at Key Switch and the solenoid thru the micro-switch, if the controller senses throttle before the micro-switch energizes the solenoid, the pre-charge resistor is the only current path from batteries to motor.

Changing directions (neutral pause) without releasing the throttle all the way would also cause the controller to be sending power to the motor via pre-charge resistor.

I know both of these are easy to avoid, but keeping the controller and solenoid activation together is safer on the circuit.

[Ribber]

Update:
Got a new cable and was able to disable the HPD. Plugged the 2-pin back into MCOR and everything is working. Drove around all weekend with no issues and pleased with new torque the 400 amp controller adds, and maybe a smidge more speed. Hopefully, all is well.