ds will not drive at times,alltrax 4865

[Cadmasterflash]

large wire, just has blue end and goes to the forward/reverse handlle

[scottyb]

There are 13 high amperage cables in the series drive system. For clarity we call these cables. There are many small wires in the control system, we call these wires. OEM cables are colored. Aftermarket cables are not.
It sounds to me like you may be loosing contact in the F&R switch. This fairly common in an older rotary switch.

[Cadmasterflash]

sorry, its the large wire that goes to the forward/reverse lever. its just has a blue wrap on the ends.

[Cadmasterflash]

I still have about 40 percent of the hair I had 30 years ago but I am pulling a little more out every time I go near this cart!!! my f/r swith visually looks clean and no discoloration, all the cables are tight and when I check my voltages they are all the same checking every piece of brass that I can touch with my meter. One thing I did notice is when I take off the pre-charge resister from the main contactor and ingage it my pack voltage goes through but it takes a few minutes to drop back down after I disengage it. ive been checking and rechecking the same things and don't know what to look at next.

[Cadmasterflash]

anyone know exactly what I can jump across to delete the f/w switch?

[Cadmasterflash]

f/r switch

[Cadmasterflash]

I spent some time on the phone with alltrax and they said it is definitely my controller and gave me the new part number to get a replacement, I called Nivel just because we have an account there and they said they don't carry alltrax anymore because of reliability problems. the guy that I talked to said that the reason my controller was taking a crap is because while the guy drives the cart he is allways going slow, his grandkids are the only ones that want to go fast. he then proceeded to tell me that with my next controller I should get some kind of add on speed control knob neither of which they have in stock and no idea when they are getting them. Does anything that I was told sound correct or does it add up to BS?

[Raystar57]

I think some BS here.
Alltrax reliability is pretty good from what I see here.
Yes some may have an issue but in general they seem great.

This is a 650A controller and that should handle the low speed driving and high amp load in that situation.
Motor will be hotter and the controller will be hotter and there could be a thermal shutdown occurring.

The F/R switch is dealing with all that extra load and will be generating heat and
the internal contacts may be loosing contact as ScottyB suggested.
The terminals can sink into the housing and loose contact.

Check F/R unit that before a controller change.
There are quite a few threads about them.

[Cadmasterflash]

thank you raystar, the f/r is like brandnew but I will take it completely off and tear it apart as to not let anything get by me. I also realized that I have 4 gauge cables and everything was bought as a kit so I don't know what the hell to do now after reading all the info on scotty b`s website. I don't know if maybe I should downgrade it so I don't have problems with it anymore. wish I knew back then what I know now.