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MSTEM Guide – Module 2: Mounting Harness and Connecting Wires (LiTime Lithium)

Mounting Harness and Connecting Wires (LiTime Lithium)

Gather Necessary Tools and Parts:

Components:

  • Wiring Harness Kit (LiTime Lithium Version)
  • E Stop Button and Harness Kit (New Version E Stop)

Tools:

Allen Wrenches

  • 5mm Allen Wrench

Box Wrenches

  • 8mm Box Wrench
  • 13mm Box Wrench
  • 14mm Box Wrench

Other Tooling Items

  • Zip Ties
  • Flush Cut Pliers
  • Hard Velcro
  • Phillips Screw Driver

Step 6 – Mounting Harness and Connecting Wires (LiTime Lithium)

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/Frame%20with%20Wiring%20Installation_LiTime%20Battery%20EVGP.pdf

6.2 – Take Figure 7, the Ohm Resistor, and lay it over top of 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 9 and 10 in wiring diagram.

6.4 – Install the 16g Black wire onto controller terminal (J1 – Grey). Please see reference number 9 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 10 in wiring diagram.

6.6 – Take Figure 5, Install Red 2G Wire connecting contactor to Main 300A Fuse Block. Please reference number 8 in wiring diagram for placement.

6.7 – Take Figure 5, Install Red 2G Wire from Contactor (-A2 Terminal ) to Controller B+ Terminal. Please reference number 11 in wiring diagram for placement.

6.8 – Take Figure 1 (Harness A), and lay out across frame as shown in wiring diagram reference number 2. 

At this moment, you wont need to secure anything so that the wire harness is movable throughout the install process. Wires will be secured in future steps.

The Terminal ends which will be laying on the left side of kart will be secured to battery at a later assembly task in another module step.

6.9 – Connect 16g Black wire (E-Stop switch wire) with small terminal end onto the lower (OFF Side) 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 20 in wiring diagram for placement.

6.11 – Connect 16g Red Wire with 5Amp Fuse to the 300Amp Fuse. Take Large Terminal End and place that under the nut that holds 300Amp Fuse into place. Place small terminal end onto top (ON Side) of On/Off Killswitch mounted on frame from Step 6. Please reference number 17 in wiring diagram for placement.

6.12 – Take Figure 2 (Harness B.1), and lay out across frame as shown in wiring diagram reference number 3. 

At this moment, you wont need to secure anything so that the wire harness is movable throughout the install process. Wires will be secured in future steps.

6.13 – Connect Red 2G Wire from Harness B.1 Anderson Plug with terminal end to Main 300A Fuse. See wiring diagram reference number 13.

6.14 – Connect Black 2G Wire from Harness B.1 Anderson Plug with terminal end to Alltrax Controller (B- Terminal). Please reference number 14 in wiring diagram for placement.

6.15 – Connect Red 2G Wire from Harness B.2 with terminals on both ends to Alltrax Controller (B+ Terminal). Reference number 12 in wiring diagram for placement. You will need to remove previously installed wire from step 6.7. 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.

6.16 – Connect Blue 2G Wire from Harness B.2 with terminal end to Alltrax Controller (J7 Terminal). Please reference number 18 in wiring diagram for placement. The other end of this wire will be installed on at a later assembly task in another module step.

Step 7 – Build and Install E Stop Switch (New Version E Stop)

7.1 – Prepare the E Stop Switch bracket and attach to the left side outer seat support. Utilize the same bolt holding seat in place, if need be to replace with a longer one you may do so for proper securing. 

  • Rotate the bracket so the big hole for E Stop is located on top and tighten with the M8 Nut. 

7.2 – Secure the E Stop Switch to mount bracket.

  • On the bottom side of the Red On/Off Button, you’ll find a large nut (25mm). This will need to be removed before inserting the button down through the hole in the E Stop Bracket.
  • Spin up the nut back onto the threaded section of the E stop body. When securing, you can use a 25mm socket (which typically isn’t common) or simply a smaller adjustable wrench, or pliers (gently without gnarring up the nut too badly or damaging anything with the E Stop itself.)

7.3 – Attach wiring harness section of E Stop to mounted Button.

  • The blue/black base of the E Stop Wiring harness should clip directly onto the top section of the E Stop Buttom as the 3 prongs line up within the quick disconnect and push into until it clips.

7.4 – Now that your E Stop switch is mounted securely, connect the red and black 16g wires with terminal eyelet ends. Please reference numbers 19 & 20 on the wiring harness diagram.

For a visual demonstration, you can refer to the following video:

NO ASSEMBLY VIDEO AT THIS TIME. PLEASE CHECK BACK SOON FOR VIDEO DEMONSTRATION.

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