Need wiring help for solinoid and controller

KillerCC

I bought a complete D&D motor, h/d solenoid, h/d f/r switch, Alltrax 500amp controller, and 4 ga cable kit. I'm confused about two things because I received no directions:
First, the controller came with a large fuse (inline), how do I incorporate it into the wiring?
Second, the 400 amp h/d solenoid has no identifying marks on the cable studs and I need to know how to wire that up?
This is for a CC DS 1997 Series cart. I have the the oem wiring schematic, but the solenoid is a completely different configuration than the original one.
PICS WOULD BE MOST HELPFUL!!!
Here's a pic of the solenoid:

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L-MZJ-400_Angel.jpg (158.0 KB, 10 views)

BGW

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sonicj

the solenoid installs just as the stock unit does. 4 studs; 2 small, 2 large. just swap everything over...

see photo for fuse

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fuse.jpg (184.9 KB, 26 views)

KillerCC

[QUOTE=sonicj;562821]the solenoid installs just as the stock unit does. 4 studs; 2 small, 2 large. just swap everything over...

So does that mean the solenoid can be wired in reverse and still work? If I wire it in reverse what will happen? Cart go backwards, nothing? I just wanna make sure I don't blow any of my new components. Thanks for your help.

scottyb

The solenoid is non-directional. It is a simple switch only and has nothing to do with direction. The activation side (small posts) are also not polarity sensitive.
Only the diode is polarity sensitive.

Curious where you got this package without any instruction.

KillerCC

Atv Outfitters. I should be done in 10 minutes. I'll post a couple pics so u can see.

KillerCC

ok, I was able to get the cart wired and it worked out AWESOME! After I was done I had about an hour and a half of battery charging time because I wanted to take it out riding that day. The batteries are brand spanking new, so I wasn't sure how long they would last, but everything was great. I rode it for at least 2 hours straight and that included some really big hills and pulling out a few stuck friends. The torque was sweet and the speed was a surprising bonus. I think the speed was more due to the 25" mud-lites though.
NOW, I did have run into a problem. I wasnt able to charge the batteries for two days and when I parked the cart in my garage, I noticed the battery light turning on and off while the key was off! I let it go and plugged the charger in the next day. After letting it charge for about 11 hours, I went out to check it and it was still charging. I could hear the batteries boiling. Do you think I need to reset the OBC? Can the OBC be reset on a series CC? I didn't have my voltmeter on me to check the pack voltage yet, but I will in the morning.

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shadowman

what your decribing is normal, brand new batteries will charge up to 16 hours cause when you get them they arn,t 100%.......make sure you break them in right or you,ll be an unhappy camper but 11 hours isn,t odd at all and as long as they arn,t bioling water all over the place your good..................

KillerCC

I let the batteries sit overnight to settle down from boiling. They did not leak at all, but they definitely were boiling. Today I'm going to check the water in them and take a volt reading. I'll test them individually and across. Hopefully you are right and I was just over-worrying.

shadowman

i,m right...........lol..............like i said just be sure to break the new batteries in right and always make sure cable connections are clean and tight...............

KillerCC

after pack testing I found a total of 51.2 volts! I'd say they are fully charged. I'll do my best to do the proper battery break in and retest them in a couple weeks. Thanks guys.