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Old 12-22-2014, 09:59 PM   #21
pastor@southwestbaptist.o
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Join Date: Aug 2013
Location: Brunswick, OHIO
Posts: 74
Default Re: First cart build...starting from scratch. Advise needed

Tonight was tear down night. Does anyone know where I can find a wiring diagram and other parts breakdown for this cart.

Cushman Commander 2100 48v

Thanks

Greg
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Old 12-23-2014, 08:03 AM   #22
JohnnieB
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Default Re: First cart build...starting from scratch. Advise needed

I'm not 100% sure of this, but I suspect the EZGO ST400 is the same vehicle with a different name tag.

At least it should be close enough to point you in the right directions.
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Old 12-23-2014, 04:59 PM   #23
pastor@southwestbaptist.o
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Default Re: First cart build...starting from scratch. Advise needed

Thank you!
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Old 04-09-2015, 02:55 PM   #24
pastor@southwestbaptist.o
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Default Re: First cart build...starting from scratch. Advise needed

I figured that I would give a little update.

After tearing down the cart that I had, I realized that the frame was VERY rusted. They must have used it to spread salt or something. So I bought a new cart that came from a factory indoor environment. It is a simple TXT model. But the frame was CLEAN CLEAN CLEAN.

After stripping it down, I made a bracket to house the 500amp controller right under the access cover.
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Old 04-09-2015, 02:58 PM   #25
pastor@southwestbaptist.o
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Default Re: First cart build...starting from scratch. Advise needed

I installed the High Torque motor from D&D.

I welded a plate to the seat mount bracket to hold the reversing contactor and solenoid.

I also flipped the side tray so that I could mount a battery there. So now it matches the other side. It was originally sort of like a "well" and the battery wouldnt fit in it. Now it is flush.
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Old 04-09-2015, 03:04 PM   #26
pastor@southwestbaptist.o
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Default Re: First cart build...starting from scratch. Advise needed

I used 2 gauge cables throughout with copper lugs.

Mounting the extra 2 batteries (I am making the cart 48v) was a little tricky. I used hanger strap and some rubber strips. Then I bolted some angle to hold it in place.

You can also see the rest of the wiring. Everything heatshrinked and tied up tight.

Heavy duty springs installed on the rear as well.

I took it out for a quick spin today. Can't wait to finish it up.

I am looking for LED 3x5 headlights for the front cowl. I am using a ST style front cowl. The lights are 3x5 stud mount.

I am also looking for a nice hunter green rear body.
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Old 04-10-2015, 02:06 PM   #27
yurtle
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Default Re: First cart build...starting from scratch. Advise needed

Only comment is if you like to play like settings like I do, you may want to install a connector before reassembling. I mounted my controller where you did, but upside down, so I could hook it up to a laptop.
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Old 04-10-2015, 02:49 PM   #28
tag50
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Default Re: First cart build...starting from scratch. Advise needed

Yurtle, could you post a picture of that set-up? I would like to see what was done to keep the elements out. Thanks

.
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Old 04-10-2015, 06:01 PM   #29
yurtle
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Default Re: First cart build...starting from scratch. Advise needed

Not perfect, but it makes the serial port accessible. You could simply plug in a serial to USB cable and tie it up. Or tweak it before covering it up. My throttle is too aggressive, as I cross a 45 MPH street, but will tone it down, one day.
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Old 04-10-2015, 06:12 PM   #30
yurtle
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Default Re: First cart build...starting from scratch. Advise needed

Actually, it wouldn't be that hard to remove the plastic cover if you want to play with settings on your setup.
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