MSTEM Guide – Module 2: Mounting Harness and Connecting Wires (Lead Acid)

Step 6 – Mounting Harness and Connecting Wires (Lead Acid)

6.1 – Download the Alltrax SR48300 Wiring Diagram to reference this portion of the project for laying out your harness and where each wire will be connecting to as you follow along with the step with this video.
Download link is https://topkartusa.net/EV/resources/SR48300%20Wiring%20Diagram.pdf

6.2 – Take Figure F, the resistor and lay it overtop the contactor. You can loosely screw on the nuts for the time being but will have to be removed in future steps.
6.3 – Take the Small 16g Red and Black wires with eyelet terminal ends and place onto small studs of Contactor. Please see reference numbers 8 and 9 in wiring diagram.
6.4 – Install the 16g Black wire onto controller terminal (J1 – Grey). Please see reference number 8 in wiring diagram.
6.5 – Install the 2 spade connector onto controller terminal (J1 Red KSI). Then connect the 16g Red wire onto one of the spades. Please see reference number 9 in wiring diagram.
6.6 – Take Figure G, Install Red 2G Wire connecting contactor to Main 250A Fuse Block. Please reference number 7 in wiring diagram for placement.
6.7 – Take Figure H, Install Red 2G Wire from Contactor (-A2 Terminal ) to Controller B+ Terminal. Please reference number 10 in wiring diagram for placement.
6.8 – Take Figure A (Harness A), and lay out across frame as shown in wiring diagram reference number 2. To keep fairly secure at this time you may want to fasten with a couple of zip ties. You may need to rearrange so this maybe a temporary secure to get things connected and how you want.
6.9 – Connect 16g Black wire (E-Stop switch wire) with small terminal end onto the lower terminal of the On/Off Killswitch mounted on frame from Step 6. Please reference number 19 in wiring diagram for placement.

6.10 – Connect 16g Red wire (E-Stop switch wire) with spade end onto the available terminal from 2 spade connector onto controller terminal (J1 Red KSI). Please reference number 18 in wiring diagram for placement.

6.11 – Connect 16g Red Wire with 5Amp Fuse to 250Amp Fuse. Take Large Terminal End and place that under nut that holds 250Amp Fuse into place. Place small terminal end onto top of On/Off Killswitch mounted on frame from Step 6. Please reference number 16 in wiring diagram for placement.
6.12 – Take Figure B (Harness B), and lay out across frame as shown in wiring diagram reference number 3. To keep fairly secure at this time you may want to fasten with a couple of zip ties. You may need to rearrange so this maybe a temporary secure to get things connected and how you want.
6.13 – Connect Red 2G Wire from Harness B with terminals on both ends to Alltrax Controller (B+ Terminal). Reference number 11 in wiring diagram for placement. You will need to remove previously installed wire from step 7.7. Both Wires will be now connected together on this terminal once installed. The other end of this wire will be installed on a later step after motor is installed onto kart.
6.14 – Connect Red 2G Wire from Harness B with stripped wire end into available open terminal of the 250Amp Fuse Block and secure wire. Please reference number 12 in wiring diagram for placement.
6.16 – Connect Black 2G Wire from Harness B Anderson Plug with terminal end to Alltrax Controller (B- Terminal). Please reference number 20 in wiring diagram for placement.
6.17 – Connect Blue 2G Wire from Harness B with terminal end to Alltrax Controller (J7 Terminal). Please reference number 17 in wiring diagram for placement. The other end of this wire will be installed on a later step after motor is installed onto kart.