Solid State Conversion Wiring Assistance Needed.

[2-old-carts]

My plan is to build a simple solid state cart for my kids to drive around the property and neighborhood.

I started with an old EZGO x444.
The motor had clearly been shorted/burned and the wiring was all heavily corroded. But.. it did run for a few weeks until the motor released the magic smoke.
The cart has no rust and is very solid. So, I removed the dead batteries, battery cables, dead motor, the old Fnr switch, the resistor coils and the mechanical throttle assembly so that I could start with a blank slate.

from D&D I purchased:
10:2 motor (170-001-0002)
400 amp controller (Alltrax sr4800-400) - receipt states "setup 5k-0"
500 amp solenoid with diode/resistor already installed
Breaker/Fuse

From Amazon I purchased:
1/0 cable kit
Heavy Duty FnR Switch assembly (states 94 & up EXGO Txt)
Curtis Type Throttle Potentiometer Pedal assembly EFP-005 (states 0-5k)

Kept from the cart: key switch.

I installed:
- Pedal and ran the 5 cables to the battery compartment.
- FnR switch in the carts original location.
- 500 amp Solenoid mounted with included 'u' bracket to front seat wall 3in under Key switch and 3in to the side of the FnR switch
- Alltrax Controller is mounted to floor/frame in center of cart between battery shelves.
- motor mounted (perpendicular) to axle.

I downloaded and used the Alltrax controller tool kit to change the SR controller from 5k-0 to 0-5k to match what the throttle/pot indicates.


That is where I am now....
Wiring.
No matter which diagram I look at, wiring the motor, FnR, Controller, & solenoid seems to be mostly straight forward.

My Problems:
1) Unfortunately none of the diagrams seem to match wire colors of my pedal/potentiometer which has 5 wires labeled Pot wiper, Pot high, Pot low, Switch Common, Switch Output.
I can't seem to find a diagram that uses these terms.

2) The Key switch seems to have different wiring in every diagram. I don't have additional solenoids or microswitches other than what is connected behind the FnR switch.

I am at a loss for the final wiring.

Should I use one of these from Alltrax (https://alltraxinc.com/documentation/#ezgo)
SR to EZGO txt Pre-1994.5 -- 1024 Replacement
--> This has a 1/2 speed rev & microswitch (ms4) that I do not have.
--> This uses a 4 wire throttle, and it's not clear what the pedal/pot wiring should be.
--> It references a 'main contactor'... is this the same as a solenoid or is this referring to a 'reversing contactor'?

SR to EZGO txt 1994.5 to Present -- 1206 Replacement
--> This includes multiple switches that I do not have (Personality, MS4-reverse, MS2-Run, charger interlock.
--> Again the main contactor..
--> 4 wire Foot switch 'ITS throttle'..?

SR Generic w/ Reverse and SR - Generic Series wiring w/ reverse don't seem to fit....


OR -------------->>>>>
Should I use the Carts unlimited EZGO Marathon wire diagram for SS conversion (https://www.buggiesgonewild.com/atta...1427249870)???
--> This is a pretty simplistic diagram, but seems to fit better than the others with one exception.. this still only uses 4 wires but my pedal/pot has 5. Perhaps my switch common is just a ground?




Thank you for any/all help.

[kgsc]

Pot wires will be wiper and one of the others based on if you want 0-5 or 5-0. Switch wires are just that.

[2-old-carts]

Originally Posted by kgsc

Pot wires will be wiper and one of the others based on if you want 0-5 or 5-0. Switch wires are just that.

While I do understand that the switch wires are common/output I don't understand where I should connect the common and the output.

As for the 3 POT wires, Wipe/Low/High...... huh? reviewing the Pre1994 diagram:
PotLow to J5
PotHigh to J4.
Is that correct?
So Where does the POT wiper cable connect?

And the key switch.... which wiring is correct?

I am concerned about miswiring the components and frying something and appreciate any/all help.

[2-old-carts]

Originally Posted by kgsc

Pot wires will be wiper and one of the others based on if you want 0-5 or 5-0. Switch wires are just that.

While I do understand that the switch wires are common/output I don't understand where I should connect the common and where I should connect the output.

As for the 3 POT wires, reviewing the Pre1994 diagram it looks like:
PotLow to J5
PotHigh to J4.
Is that correct?
So Where does the POT wiper cable connect?

And the key switch.... which wiring is correct?

I am concerned about miswiring the components and frying something and appreciate any/all help.

[kgsc]

The switch wires really don’t matter on orientation. It will just just wire in where the pedal switch is in your diagram.

As for the throttle you need the wiper wire and either the pot high or low depending on if you are going to use 0-5 or 5-0k

[2-old-carts]

I am started with a clean slate, no existing wiring, no motor, no solenoid, no accelerator/potentiometer...
Only thing from original cart is the key switch....

Used the CartsUnlimited Diagram from the BGW site.

Components:
Controller: Altrax SR48400
FnR Switch: Heavy duty EZGO
Accelerator: Curtis Type 0-k5 potentiometer/throttle pedal with 5 cables labeled POT High, POT Low, POT Wiper, Switch Output, Switch Common.
- I used POT High in J4, and POT wiper in J5. POT low was NOT used.
- SwOut went to FnR, SwCommon went to Solenoid + spade connector.

Solenoid: Curtis/Albright SW180-93 500Amp
--- documentation indicates :
- BOTH large top posts are positive (and connected by a capacitor)
- the top two spade connectors are positive
- the bottom two spade connectors are negative
- the right hand side of the spade connectors have a diode connecting the + and the -.
Wired in this manner, when I turned the key on everything seemed OK.
When I pushed the accelerator pedal the diode between the + and - spade connectors on the solenoid blew out violently.

I have double checked that I wired according to the diagram but obviously I have done something wrong.

Can anyone lend some expertise to help me figure this out?

Thank you.

[2-old-carts]

Originally Posted by 2-old-carts

I am started with a clean slate, no existing wiring, no motor, no solenoid, no accelerator/potentiometer...
Only thing from original cart is the key switch....

Used the CartsUnlimited Diagram from the BGW site.

Components:
Controller: Altrax SR48400
FnR Switch: Heavy duty EZGO
Accelerator: Curtis Type 0-k5 potentiometer/throttle pedal with 5 cables labeled POT High, POT Low, POT Wiper, Switch Output, Switch Common.
- I used POT High in J4, and POT wiper in J5. POT low was NOT used.
- SwOut went to FnR, SwCommon went to Solenoid + spade connector.

Solenoid: Curtis/Albright SW180-93 500Amp
--- documentation indicates :
- BOTH large top posts are positive (and connected by a capacitor)
- the top two spade connectors are positive
- the bottom two spade connectors are negative
- the right hand side of the spade connectors have a diode connecting the + and the -.
Wired in this manner, when I turned the key on everything seemed OK.
When I pushed the accelerator pedal the diode between the + and - spade connectors on the solenoid blew out violently.

I have double checked that I wired according to the diagram but obviously I have done something wrong.

Can anyone lend some expertise to help me figure this out?

Thank you.

Bump.

Anyone have any hints/help to offer?