006 Club Club Car DS 1999 All Wiring (Alltrax 500)

This covers all of the wiring of a Club Car DS to a Alltrax DCX 500 controller. This is the final run-through after doing the bulk of the wiring, as well as connecting the batteries, along with troubleshooting when it didn't work out.
First 10 minutes is wiring
10:52 battery hookup
13:52 on-board charge computer and charge receptacle
17:27 foward/reverse switch
18:16 nuts and bolts (shaky camera warning)
20:02 speed sensor not needed
21:44 cable ring terminal modification and battery cables
25:27 first power-up test - failure
26:41 battery voltmeter test
28:30 success - tow/run switch and obc wire
29:30 power on for real, f/r mixed up
31:04 proper operation
31:57 follow up plans
33:55 wife acceptance factor
34:24 driving test

[@donaldfennell971]

Learned a lot here. I have a 2001 DS, I get 16 MPH with 12" wheels. I would like get up to 23 MPH and have a RUN/TOW switch, which would require a Harness upgrade, 400A Controller and maybe a Motor upgrade.

[@mrhoya14]

At 29:02 i dont even have that connector.. For the tow/run switch.. Please help.. I found the red/white wire is connected to the b- post from controller, looks like it runs to the key ignition from the controller

[@mrhoya14]

So did you put the yellow wire where the tow/run suppose to be?.. My 2000 cart is not running at all

[@armchairtechnician7725]

Hopefully you got it by now, but for anyone else, yes I went with that tennis wire instead of a switch.

[@mrhoya14]

I tested my potentiometer and it seems to be in working condition.. Just cant get the cart to move still

[@armchairtechnician7725]

Sorry for the late response. If you hear the click, it should be working. Only thing I can think of is the computer or the wiring from the solenoid to the motor. I would try on buggies gone wild. They have a forum for electric club cars. www.buggiesgonewild.com/

[@509Mrzoe]

Where do you find wiring diagram

[@mrhoya14]

How do you test voltage at the ignition?

[@wallyfeldon2872]

any chance you can send me a copy of the wiring diagram?

[@mrhoya14]

I hear a click when i press on the pedal but the cart doesnt move.. Batteries test at 48v

[@yourtechjohn]

28:30 is where I diagnose my tow/run. I had a connector, but had to put a wire in since I didn't have a switch. Without the switch/wire, you won't hear a click at all. You should hear a click when you turn the key. Then, there is a Forward and Reverse switch, one way will get you a backup buzzer (if connected) and the other will not. There's also a 3rd, "neutral" position.

[@mrhoya14]

@@yourtechjohn i hear the click whenever i press the gas pedal either on forward or reverse with the key on..

[@mrhoya14]

@@yourtechjohn do all the 3 metal pins from the switch should lift up when on reverse? When i put it on forward it only lifts up one metal pin. But doesnt go anywhere..

[@charleym977]

@@mrhoya14 i got the same problem man.

[@hillbillybassfisherman8181]

have you ever try the 700 amp controller ?

[@armchairtechnician7725]

Nope, still on the same controller

[@hillbillybassfisherman8181]

why didnt you do away with the computer to controll nothing but charging that just a problem waiting to happen i dont see no reason to have that.cause the charger is not a automatic it dont maintain the battery.i bought automatic maintainer it can sit there a year an the battery pack ready to go..if you use battery charger with these once it shuts off it want start back so why have a problem on the cart

[@armchairtechnician7725]

I have done just that actually. I have an external automatic charger and they onboard is not connected at all.