03 Club Car DS Factory Limo Hop Up Build in process Questions

[XxDoubledxx]

Originally Posted by Wakko47

Those are nice cables...did you assemble them or get them that way? Where from?

I’m making the lengths as I go.

[R&TBabich]

Originally Posted by kgsc

Please tell me you didn’t bolt that to the frame Major no no. You can buy a fuse holder to do the same but never connect directly to the frame. ....

Here' a better angle of the fuse block.
I think next time I will 3D print the block, the studs are just regular SS bolts.
I'm going to add a -48V stud on the other side to keep all the negative leads off the battery.
I had some leftover 1 ga cable from a boat project so I made cables to connect the batteries to the motor.
The previous owner had installed a 2 ga battery cable set when he changed the batteries.

[kgsc]

Okay, much clearer now. I assume the bolt heads are recessed ?

[XxDoubledxx]

Originally Posted by R&TBabich

I didn't like the idea of the Alltrax 400A fuse hanging off a battery terminal so I mounted it on the frame rail behind the batteries.
Now I don't have to pull the battery terminal cable to disconnect, that can be done at the fuse.

Thanks for the advice. I was originally planning on just mounting the fuse directly to the main solenoid.

[XxDoubledxx]

Originally Posted by kgsc

As for wiring your cart is based on a DS so get the wiring diagram for that for the wiring colors for key switch and throttle. The rest you will just have to figure out.

Thanks for the advice. I just haven’t found a wiring diagram for this particular built.

I take it that the main solenoid shouldn’t matter how I use it meaning #1 and # 2 post as long as the diode is orientated correctly right?

PS if I could just figure it out I wouldn’t have made this post for some help.

[R&TBabich]

Originally Posted by XxDoubledxx

.... I take it that the main solenoid shouldn’t matter how I use it meaning #1 and # 2 post as long as the diode is orientated correctly right? ....

Correct.
Mine is wired with both +'s on the right.

[kgsc]

Originally Posted by XxDoubledxx

Thanks for the advice. I just haven’t found a wiring diagram for this particular built.

I take it that the main solenoid shouldn’t matter how I use it meaning #1 and # 2 post as long as the diode is orientated correctly right?

PS if I could just figure it out I wouldn’t have made this post for some help.

Fair enough.. Maybe this will help. https://alltraxinc.com/wp-content/up...S-WIRE-DIA.pdf

Are the original wires and throttle box there?

[R&TBabich]

Originally Posted by kgsc

.... I assume the bolt heads are recessed ?

Yes, there is some sort of potting in there, too.

[kgsc]

And this one

[XxDoubledxx]

Originally Posted by XxDoubledxx

👍 you are correct

Originally Posted by kgsc

Fair enough.. Maybe this will help. https://alltraxinc.com/wp-content/up...S-WIRE-DIA.pdf

Are the original wires and throttle box there?

If by throttle box you mean the MCOR then yes it’s there with the factory wires/connectors. That’s all running to the back of the cart. Those seem to be the easiest to wire in.

The cart was already upgraded some but I pulled that stuff out to install the new items. I also wanted to eliminate the factory F-N-R cluster along with all the big wires running 12ft length of the cart and just install the toggle switch and only run a few small wires up front to the rocker switch. Parts removed were a 2006 D&D motor, Alltrax Axe 2007 , and a Allright SW80 main solenoid.

I’m mainly having a wiring issue between the main solenoid, controller, the two F-N-R solenoids, and the motor.

I have those diagrams. One in the manual and one I found and printed but they don’t seem to correspond with my build. Or maybe I’m over thinking it.