INSTALLATION INSTRUCTIONS Club Car DS Installation Notes
Transcript of INSTALLATION INSTRUCTIONS Club Car DS Installation Notes
1551 S. Vineyard Avenue Ontario, CA 91761
(909) 923-1973
INSTALLATION INSTRUCTIONS
Club Car DS
Installation Notes
CURTIS 1234, 1236 OR 1238
AC INDUCTION MOTOR/ CONTROLLER
Page 2 of 16
Installation Instructions Club Car Curtis Controller
1. Disconnect Negative Battery Cable, Disconnect Positive Battery Cable.
2. Remove cart’s rear body. (Removal of front body is optional).
3. Disconnect all Motor and Controller wires.
4. Remove original Motor and Controller (remove controller mounting plate, if equipped).
5. Remove original wiring harness. Unplug any connector (cut as little as
possible). If equipped with Rear Brake Lights Kit (DIAGRAM 2.1), label and keep factory wires from the brake pedal/ park switch. Theses wires will be reused to enable the brake lights. (See DIAGRAM 2.2 & 2.3)
6. Install new AC 9 Motor. (Use supplied ¼-20 Bolts, reuse original 5/16-18 Bolt
Do not over torque Motor Bolts). 7. If clearance from the passenger shock mount to the motor’s fan shield is less
than one inch (viewing from the top), cut/trim passenger side rear shock ( See PICTURE 1.1 for reference). This procedure is not needed if cart has been lifted.
8. With the supplied controller mounting plate, reposition the controller plate
supports to the opposite side. The supports were originally installed such way for shipping purposes. Adjust the supports as needed after reposition.
9. Install the Controller & Factory Main Contactor to mounting plate. (Use
supplied ¼-20 bolts and lock-washers). Main plug on controller should be positioned to the bottom right of plate.
10. Install the Controller mounting plate in cart. Top bracket mounts to the
bottom of the body support. See PICTURE 1.2
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11. Install the battery charging equipment. The charging equipment would be
either the factory Charge Computer or an on-board Delta-Q Battery Charger. 11.1. For Factory Charge Computer, see PICTURE 1.2 and DIAGRAM 2.4 for
reference. 11.2. For on-board Delta-Q Battery Charge, see PICTURE 1.3 and DIAGRAM
2.5 for reference. 12. Connect Motor Cables from the controller to the AC9 Motor at each
appropriate phase. Motor Cables and Battery Cables should be at least #2 AWG. See DIAGRAM 2.10 for reference.
13. Connect one side of the Main Contactor to the Fuse Post on the Controller.
14. Connect Negative Battery Cable to the controller. (DO NOT connect to Battery
at this point).
15. Install Wiring Harness. See PICTURES 2.1 & 2.2 and DIAGRAMS 2.9
16. Connect the throttle connectors (R2 & R3) from the wiring harness to the throttle module. See Diagram 2.9
17. Connect wires to FWD/REV switch, See DIAGRAM 2.6
18. Drill a 2 1/16” hole in the dash panel for the Dash Display. See DIAGRAM 2.8
for Dash Panel Connections
19. Plug cable with 8 pin connector into the back of the Dash Display.
20. Connect Red Wire to one side of Key switch. See DIAGRAM 2.8
20.1. If charge computer is used, connect orange wire from charge light to the same side of the key switch as red wire.
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21. Connect Blue wires to key switch (See DIAGRAM 2.8). Extra Blue jumpers/splices are required to connect the Golf/Street Switch, and optional Brake light Relay.
22. Connect the Yellow wire to the + (positive) side of the reverse buzzer, and the Gray wire to the – (negative) side. See DIAGRAM 2.8
23. Connect a Blue wire from the key switch to terminal 2 on the Golf/Street
switch, and the Brown wire to terminal 1. (Golf Mode is selected when terminals 1 and 2 are connected together). See DIAGRAM 2.8
24. For carts equipped with Rear Brake Light Kit, install a 12VDC automotive type
relay in a suitable location where both factory and system wires can be connected together. The factory brake wires were disconnected and labeled at step #5.
The below connections can be reviewed by using the DIAGRAMS 2 . 2 , 2 . 3 & 2 . 8
24.1. Connect the factory +12V source wire to the relay at terminal #30. 24.2. Connect the factory RED wire of the rear brake lights to the Brake
Relay at terminal #87. 24.3. Connect a Blue wire from the key switch to the Brake Relay at
terminal 86. 24.4. Connect the Orange wire to the Brake Relay at 85 terminal.
25. Connect Orange/White wire to the – (negative side of the Main Contactor), and Blue/White wires to the + (positive side). Remove any resistor, diode.
26. Connect Fuse Wire and the + Battery cable to the Main Contactor. If equipped with Charge Computer, Connect Red Wire from Charge Computer
to the same Terminal. (Yellow wire on Charge Computer not used. See DIAGRAM 2.4).
27. Plug in Encoder Cable.
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28. DOUBLE CHECK ALL CONNECTIONS.
29. Secure all wires, harnesses and cables to the cart’s frame by using tie straps. 30. Install 10 Amp Fuse at the fuse holder in the system harness.
31. Connect – (negative) Battery Cable.
32. Test Cart on jack stands.
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Driving the car with the A-C Drive System
When key switch is first turned on, the system needs about 2 seconds to come online. After this time has expired, select the desired drive direction at the Forward/Reverse switch and press the accelerator pedal. The drive wheels could be in either direction when first turned on. BDI: (Dash Display), the BDI will display Battery Charge level (LED’s at bottom) as well as text messages. BDI Message Mode MPH Cart in Street Mode (displays vehicle speed) GOLFMODE Cart in Golf Mode (see note below) REVERSE Cart in Reverse direction (see note below) LOWBATT Cart in Limp Home mode (see note below) Street Mode gives the vehicle a Max speed of 25 Miles per hour. Acceleration & Regenerative Brake torque are set at maximum level. When in Golf Mode the cart speed is limited to 12 Miles per hour. Acceleration & Regenerative Brake torque are also reduced. Drive Mode can be changed on “The Fly”. There is no need to stop the vehicle when changing from Street to Golf or vice-versa. When Cart is in Reverse, speed is reduced to 8 Miles per hour. Acceleration & Regenerative Braking torque are also reduced. Limp Home mode is automatically activated when the Battery charge level has dropped below 20%. The maximum cart speed is restricted up to 15 Miles per hour at Street mode. It is recommended to charge the batteries as soon as possible to prevent damage to the batteries from being over discharged.
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CLUB CAR FACTORY BRAKE LIGHT KIT WIRING DETAIL
-DIAGRAM 2.1
Page 8 of 16
HPEV AC-9 SYSTEM BRAKE LIGHT WIRING DETAIL
-DIAGRAM 2.2
BLUE
(COMMON)
RED/ YELLOW
(Normally Closed)
PARK
SWITCH
HPEV SYSTEM
WIRING
HARNESS
BLUE
(COMMON)
PURPLE
(Normally
Closed)
BRAKE
SWITCH
TO FACTORY
BRAKE LIGHT
FROM +12V
BATTERY
DISCONNECT FACTORY BRAKE
LIGHT WIRES AND RECONNECT TO
A 12V AUTOMOTIVE RELAY
(SEE DIAGRAM 2.3)
RED
BLUE
NORMALLY
CLOSED
NORMALLY
OPEN
COMMON
RED / YELLOW
BLUE
NORMALLY
CLOSED
NORMALLY
OPEN
COMMON
PURPLE
PARK SWITCH
WIRING DETAIL
BRAKE SWITCH
WIRING DETAIL
Page 9 of 16
BRAKE LIGHT REWIRING RELAY DETAIL
-DIAGRAM 2.3
85
87
86
30
BRAKE LIGHT
RELAY
TO FACTORY
BRAKE LIGHTS
BLUE
FROM +12V
BATTERY
RED
ORANGE
FROM HPEVS
SYSTEM
HARNESS
FROM HPEVS
SYSTEM
HARNESS
Page 10 of 16
CLUB CAR WIRING HARNESS with CHARGE COMPUTER (ORIGINAL EQUIPMENT)
- DIAGRAM 2.4
RED-YELLOW
BLUEPARK SWITCH
PURPLE
BLUEBRAKE SWITCH
THROTTLE
CONNECTIONS
BLUE
GREEN
BLACK/ WHITE
PURPLE/ WHITE
YELLOW/ WHITE
WHITE
RED-YELLOW
FORWARD/ REVERSE
SWITCH
YELLOW
SEE DIAGRAM 2.7
6 PIN PLUG TO
MOTOR ENCODER
35 PIN CONNECTOR
GRAY
BLUE
BROWN
ORANGE
RED
YELLOW
WHITE/ RED
8 PIN DISPLAY PLUG
BROWN FORM ORIGINAL
CHARGE COMPUTER IF
USED
Main
Contactor
WIRE BUNDLE
BLUE/ WHITE
ORANGE/ WHITE
+
-
FUSE 10A
TO BATTERY
POS (+)
#2 CABLE
TO CONTROLLER POS (+)
MAIN FUSE #2 CABLE
RED
YELLOW (NOT USED) BROWN
GRAY
10 GAUGE
BLACK
CHARGER
PLUG
TO
BATTERY
POS. (+)
10 GAUGE
BLACK
EXTEND WIRE AND
CONNECT TO
BATTERY NEG. (-)
HOLE IN
CHARGE
COMPUTER
SEE DIAGRAM 2.8
DASH PANEL
Page 11 of 16
CLUB CAR WIRING HARNESS with ON BOARD DELTA-Q BATTERY CHARGER
- DIAGRAM 2.5
RED-YELLOW
BLUEPARK SWITCH
PURPLE
BLUEBRAKE SWITCH
THROTTLE
CONNECTIONS
BLUE
GREEN
BLACK/ WHITE
PURPLE/ WHITE
YELLOW/ WHITE
WHITE
RED-YELLOW
FORWARD/ REVERSE
SWITCH
YELLOW
SEE DIAGRAM 2.7
6 PIN PLUG TO
MOTOR ENCODER
35 PIN CONNECTOR
GRAY
BLUE
BROWN
ORANGE
RED
YELLOW
WHITE/ RED
8 PIN DISPLAY PLUG
Main
Contactor
WIRE BUNDLE
BLUE/ WHITE
ORANGE/ WHITE
+
-
FUSE 10A
TO BATTERY
POS (+)
#2 CABLE
TO CONTROLLER POS (+)
MAIN FUSE #2 CABLE
DASH
PANNEL
SEE
DIAGRAM 2.8
GREEN
RE
D
BL
AC
K
WH
ITE
TO BATTERY NEG. (-)
TO BATTERY POS. (+)
WHITE - NEUTRAL
BLACK - HOT
GREEN - GROUND
110 VOLT AC
PLUG
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FORWARD/ REVERSE SWITCH DETAIL - DIAGRAM 2.6
4
5
6
1
2
3
WHITE
RED/ YELLOW
YELLOW
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1
2
CLUB CAR DASH PANEL WIRING DETAIL - DIAGRAM 2.8
DASH
DISPLAY
85
87
86
30
GOLF / STREET
SWITCH
BRAKE LIGHT
RELAY
REVERSE
BUZZER
KEY
SWITCH
MENU
TO BRAKE
LIGHTS
+12V IN
BLUE
ORANGE
ORANGE
BLUE
YELLOW
GRAY
BROWN
RED
WHITE / RED
BDI CABLE
CHARGE LIGHT
BROWN
(FROM CHARGE
CONTROLLER IF USED)
BLUE
BL
UE
Page 14 of 16
VISIO
12/29/10 1 1
85 86
87 30
BRAKE
LIGHTS
RELAY
1010-CLUBCAR-001
NONE
NOTICE: This drawing is the property of Hi Performance Electric Vehicle Systems Inc., and/or its subsidiaries and affiliates
(individually and collectively “HPEVS”), and contains highly proprietary, confidential, and trade secret information of HPEVS. The
recipient of this drawing agrees (a) to use the information contained herein for the purpose for which it was furnished by HPEVS
(b) to return this drawing upon HPEVS request. This notice shall appear on any complete or partial reproduction of this drawing.
DRW SIZE BCAD FILECAD LOC.CAD TYPE
OPER. NO. UNIT DRAWING
TITTLEDETAILDESIGN
CHECKED SAFETY
SCALE DATE REVISION
SHEETHPEVS
OF
CLUB CAR
SYSTEM SCHEMATICS
PURPLE 18 AWG
R1
ORANGE/ WHITE18 AWG
GOLF / STREET SWITCH
I/O GROUND
PEDAL INTERLOCK
MENU BUTTON
POT WIPER
BRAKE SWITCH
FOWARD
12V POWER CNTRL
5V POWER CNTRL
TX SERIAL
RX SERIAL
ENCODER PHASE A
ENCODER PHASE B
REVERSE
KSI
BRAKE RELAY
MAIN CONTACTOR COIL
COIL RETURN
BLUE 18 AWG
GRAY 18 AWG
ORANGE 18 AWG
BROWN 18 AWG
BLACK/ BLUE 18 AWG
GREEN 18 AWG
WHITE/ RED 18 AWG
BLUE/ WHITE 18 AWG
YELLOW/ WHITE 18 AWG
YELLOW 18 AWG
RED/ BLUE 18 AWG
RED/WHITE 18 AWG
GREY/ BLUE 18AWG
GREEN/ WHITE 18 AWG
TAN 18 AWG
TAN/BLACK 18 AWG
WHITE 18 AWG
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
N/C
BACK UP BUZZER
N/C
MOTOR TEMP SENSOR
N/C
N/C
N/C
N/C
N/C
N/C
N/C
N/C
N/C
N/C
N/C
BACK UP BUZZER
S2
RED 18AWG
+48V OR 72V
TO BRAKE LIGHTS
BRAKE SWITCH
(NOTE *6)
S3
R6MOLEX MINI FIT JR
39-01-2080
Note: Pins 2, 3, 4, & 7 are
not connected
BLUE 18AWG
KEY SWITCH
10A
MENU BUTTON
(NOTE *3)
GOLF / STREET
SWITCH
REVERSE
P4DEUTSCH
DTM-04-6P
I/O GROUND
TX SERIAL
12V POWER CNTRL
KSI
AMP
776164-1
BLUE 18AWG
FOWARD
FORWARD / REVERSE
SWITCH
MAIN
CONTACTOR
(NOTE *4)
+A
1-A
2
R4DEUTSCH
DTM-06-6S
W V U
UVW
B +
B -
35
PIN
CO
NN
EC
TO
R
(SE
E R
1)
+ -
MOTOR
YELLOW/ BLACK 18 AWG
RX SERIAL
DISPLAY
1
5
6
8
S1
POT HIGH BLACK/ WHITE 18 AWG
POT LOW PURPLE/ WHITE 18 AWG
BLUE 18AWG
BLUE 18AWG
NOTES:
(*1) BLACK AND WHITE NOT USED ON 2 WIRE POT. SELECT TYPE 3
PARAMETER.
(*2) NORMALLY CLOSED SWITCH. OPEN FOR PARK. IF SWITCH NOT
USED, RED/YELLOW WIRE IS CONNECTED TO BLUE.
(*3) MENU BUTTON IS OPTIONAL USE WITH DISPLAY. NORMALLY
OPEN; MOMENTARY
(*4) REMOVE ANY DIODES OR RESISTOR FROM MAIN CONTACTOR.
(*5) USE 400A FUSE IN 650 SYSTEM. USE 300A FUSE IN 350 SYSTEM.
(*6) NORMALLY CLOSED. CONTACTS MUST BE CLOSED WHEN BRAKE
PEDAL IS PRESSED; OPEN WHEN BRAKE PEDAL IS NOT PRESSED.
(*7) MOTOR TEMP SENSOR NOT USED FOR GOLF CART APPLICATION.
(*8) SPLICE S4 TO BE PERFORMED BY THE END USER.
POT WIPER
POT HIGH
POT LOW
MOTOR ENCODER
CABLE
BLACK/ BLUE 22 AWG
RED/ WHITE 22 AWG
TAN 22AWG
TAN/ BLACK 22 AWG
BLACK 22 AWG
PURPLE 22 AWG
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
R5MOLEX SL SERIES
50-57-9405
MO
TO
R E
NC
OD
ER
MOTOR TEMP
SENSOR
(NOTE *7)
N/C
12V IN
BLUE 18AWG
RED/ YELLOW 18AWG
BLUE 18AWG BLUE 18AWG
PARK SWITCH (NOTE *2)
BLACK/ BLUE 18 AWG
GREY/ BLUE 18AWG
GREEN/ WHITE 18 AWG
RED/ BLUE 18 AWG
YELLOW/ BLACK 18 AWG
BLACK/ BLUE 18 AWG
BLACK/ BLUE 18 AWG
TAN 18 AWG
TAN/ BLACK 18 AWG
RED/ WHITE 18 AWG
S4
(NOTE *8)
400A
(NOTE *5)
C
A
B
21
THROTTLE
MODULE
R2DEUTSCH
DT-06-3S
R3DEUTSCH
DT-06-2S
E
REV ORIGINATOR DESCRIPTION APPROVED
A INITIAL RELEASE
B Added R2 & R3 connectors
E
Updated revision sequeence to match
revision sequence recorded from
supplier. Previous part number recorded
by the supplier will be obsolete. New
part number is listed in the drawing t it le
block. M issing dimensions were addded 11/15/2011
REVISIONS
HPEV SYSTEM WIRING DETAIL - DIAGRAM 2.9
Page 15 of 16
U V W
B + B -FUSE
CONTROLLER
MOTOR
35
PIN
CO
NN
EC
TO
R
Main
Contactor
BLUE/ WHITE
ORANGE/ WHITE
+ -
6 PINTO WIRING
HARNESS
U
W
V
FRONT OF
CART
HIGH CURRENT WIRING DETAIL - DIAGRAM 2.10
Page 16 of 16
PICTURE 1.1 PICTURE 1.2
PICTURE 1.3 PICTURE 2.1
PICTURE 2.2 CONTROLLER MOUNTING