Help me solve build problems please!

jasonfichter

I just bought a 2003 38v PDS TXT. It came with just a frame and wires going to the ignition and another set to the gas pedal. I'm trying to convert it to 48v with a Madjax 600 controller and scottyb's heavy duty solenoid.

Can someone tell me what other harnesses I'm missing? I just realized I don't have a run tow switch so I bought that and the harness.

I also can't figure out where the wires go that come out of the harness from the ignition. The plug does into the Madjax personality module and then the other ring terminals go where? There is also a red wire that appears to have been cut off about a foot up from the connector for the personality module; any idea what that is?

Also the Madjax says to connect the wire to the motor on the M post. However it doesnt specify where to connect the second wire that comes off the motor?

I also bought a 48V onboard charger; it has three wires. A positive to go on the first battery, a negative to go on the last battery, and a blue wire with a female spade connector on it. Im assuming its for a reed switch but how would that work considering there is no charging receptacle because it is onboard?

Finally on the ignition there are two wires one white, and one white and yellow, which wire do I connect the switched input for the Madjax 48v to 12v converter to?

Im also very bad at reading wiring diagrams so if you can explain it for dummies please. Electronic wiring is my nemesis.

Thanks so much for your help guys! I know i'm asking a lot on my first post.

BGW

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Helirich

I have a on board charger and it does have a charge port. The port is just a regular 110v plug that mounts in the same place as a normal charge port.



Mine doesn't have any reed switch. Yours may be more advanced than mine. The port I have looks nice with a rubber cover when I don't have a extension in it. Under the seat, it has a short cable and another female 110v that the charger plugs into. It would be nice to have the reed switch. Maybe you should contact the manufacturer of the charger.

jasonfichter

Mine never came with a charging receptacle. I called Lester the maker of the charger and their tech support doesn't answer.

Does anyone have any other ideas about my other dilemmas?

JohnnieB

Sounds like you're trying to do three separate projects simultaneously.

Do them one at a time and it'll be less confusing.

Easiest one first: You have new batteries and they need to be charged before first use, so connect the positive and negative output wires as you described in your post. Leave the third wire disconnected (Tape the bare spade terminal so it doesn't short against anything).

If it is a charger designed for on-board use, the purpose of the third wire is most likely to disable the cart while on charge, the same function as the reed switch. but is not needed to charge the batteries.

What is the Make/Model of the charger?

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Attached is a picture of the 36V PDS adapter.
You need to plug plugs into four of the six jacks.
Jack labeled 1: 3-Pin plug from speed sensor on motor.
Jack labeled 2: 4-Pin plug from pedal box. (ITS and Pedal switch)
Jack labeled 3: 4-Pin plug from Run/Tow switch.
Jack labeled 4: 10-Pin plug from cart's control wiring harness.

The three wires with ring terminals, Yellow, Blue and Red, go to the solenoid.
Yellow and Blue go to the small terminals (coil) and the Red one goes to the battery side large terminal.

The red one that is cut off may have gone to the reverse beeper and/or the reed switch. The other end connects to Pin-4 in the 10-Pin plug.

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The remote on wire from the converter should be connected to the keyswitch terminal with the wht/yel wire on it.

jasonfichter

Thank you so much for helping me out! I will try to wire it up later on today.

First off, the exact charger is a Lester Electrical Summit Series II 48V/13A / 27800G054FB1W1 / 27800. Is there a wire I can connect the third wire to on the charger so that the cart doesn't move when plugged in? That would be a very nice feature so I don't rip the cord out of the wall.

As far as the wiring I have/ordered all the harnesses except the wires for the speed sensor. Since I ordered a Admiral D2 I'm assuming it is going to come with the wires? Also does anyone know if it comes with the field wires?

Also where in this whole mess of wires do I connect the meter too? Can I run it off the same wires that are powering the madjax converter?

Finally do you know how the madjax controller is wired up? Does B+ have 2 cables going to it? (I think it was b+ not sure)

Thanks again

JohnnieB

1. The Lester 27800 manual (attached) says that wire is attached to B- when the charger is active, so I'm not sure if it would be a good idea to connect it directly to the controller (via the reed switch input --- J1 Pin-4 on the PDS wiring harness). Also looks like the feature has two factory configurations and I cannot decipher the model number to tell which way yours is configured . See bottom of page 10 in manual.

2. The motor will not come with a 3-Pin plug that fits the PDS adapter you have. Most likely will have a short pigtail with a Deutsch DT04 - 3P connector. You need the speed sensor cable and end off the old (stock) PDS motor to plug into the PDS adapter.

3. No, neither motor nor controller comes with the F1 & F2 cables. Build them from 10ga stranded wire. They need to be flexible since motor rocks back and forth during operation.

4. It depends on the meter. If it is a two wire meter, the wires feeding 48V to the 48V to 12V converter will work.

5. In the installation manual (attached), shows the A2 cable from motor connected to the battery side large terminal on the solenoid along with a short cable that goes to B+ terminal on controller. The A2 cable can be connected at either end of the short cable. Personally, prefer connecting both the A2 cable and short cable on the controller's B+ terminal on. (Ever so slightly more efficient.)

Attached Files

	39251_F.pdf (1.04 MB, 0 views)
	25-001-07-installation-instructions.pdf (11.21 MB, 0 views)

jasonfichter

Again thank you so much for all of your help.

I will give the battery charger people a call again too see about using the third wire as a reed switch type thing. I believe my charger is configured for wet cell batteries which is what I'm using.

My cart didn't come with the speed sensor cable so I just ordered one and will see how it works out. I'll probably just cut the end off the motor cable and connect the two. Is there a pin out to use so I know which wire's to connect?

I will make the field cables as soon as I get the motor on Tuesday.

With the meter if I use the cables going to the converter the meter would be on constantly correct? I don't think I want it on all the time.

I connected up the solenoid and all the wires to the controller with no issues. Thank you for the guidance.

JohnnieB

For the speed sensor, the Black wire is negative and the Red wire is positive and the white wire is the signal in the stock PDS cable. The motor may use a different color code.

The Black and Red will probable be the same, and the third wire will be the signal.

Probably be a good idea to ask whoever you got the motor from for which wire is which on the motor's speed sensor.

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Connect the meter's positive wire to the converter's remote on wire that is connected to the keyswitch.

jasonfichter

I received my meter today and its a three pin meter. (+,-,C)

Also do you know what size bolts connects the motor to the differential?

And is the washer inside the motor necessary?

JohnnieB

1. Connect the + and - to the the battery pack + and - (Feed to 48V to 12V will work) and the third wire to the switched output from the keyswitch.

2. 1/4-20 threads. Depth of threaded mounting holes in motor case is a bit over 1/2"

3. Without the rubber spline bumper, you make get some rattling and other noises.