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 ...
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
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 Page 2 of 16
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.
Page 3 of 16
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. Page 4 of 16
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.
Page 5 of 16
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 MPH GOLFMODE REVERSE LOWBATT
Mode Cart in Street Mode (displays vehicle speed) Cart in Golf Mode (see note below) Cart in Reverse direction (see note below) 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.
Page 6 of 16
CLUB CAR FACTORY BRAKE LIGHT KIT WIRING DETAIL -DIAGRAM 2.1
Page 7 of 16
HPEV AC-9 SYSTEM BRAKE LIGHT WIRING DETAIL -DIAGRAM 2.2 PARK SWITCH WIRING DETAIL
RED/ YELLOW (Normally Closed)
NORMALLY CLOSED
COMMON
BLUE NORMALLY OPEN
PARK SWITCH
RED / YELLOW BLUE (COMMON) NORMALLY CLOSED
COMMON
BLUE NORMALLY OPEN
PURPLE
BRAKE SWITCH WIRING DETAIL PURPLE (Normally Closed)
BRAKE SWITCH
BLUE (COMMON)
HPEV SYSTEM WIRING HARNESS
FROM +12V BATTERY
DISCONNECT FACTORY BRAKE LIGHT WIRES AND RECONNECT TO A 12V AUTOMOTIVE RELAY (SEE DIAGRAM 2.3)
RED
TO FACTORY BRAKE LIGHT
Page 8 of 16
BRAKE LIGHT REWIRING RELAY DETAIL -DIAGRAM 2.3
RED
TO FACTORY BRAKE LIGHTS
ORANGE FROM HPEVS SYSTEM HARNESS FROM HPEVS SYSTEM HARNESS
87
BLUE 86
85
30
BRAKE LIGHT RELAY
FROM +12V BATTERY
Page 9 of 16
CLUB CAR WIRING HARNESS with CHARGE COMPUTER (ORIGINAL EQUIPMENT) - DIAGRAM 2.4 FORWARD/ REVERSE SWITCH SEE DIAGRAM 2.7
WHITE RED-YELLOW
RED-YELLOW BLUE
YELLOW PURPLE BLUE 6 PIN PLUG TO MOTOR ENCODER
PARK SWITCH
BRAKE SWITCH
BLUE GREEN BLACK/ WHITE PURPLE/ WHITE
35 PIN CONNECTOR
THROTTLE CONNECTIONS
YELLOW GRAY
YELLOW/ WHITE WIRE BUNDLE
DASH PANEL
BLUE BROWN
SEE DIAGRAM 2.8
ORANGE RED BROWN
YELLOW (NOT USED)
FUSE 10A
WHITE/ RED 8 PIN DISPLAY PLUG
RED 10 GAUGE BLACK
TO BATTERY POS (+) #2 CABLE BLUE/ WHITE
CHARGER PLUG
GRAY
+
BROWN FORM ORIGINAL CHARGE COMPUTER IF USED
Main Contactor ORANGE/ WHITE
10 GAUGE BLACK
TO CONTROLLER POS (+) MAIN FUSE #2 CABLE
HOLE IN CHARGE COMPUTER
TO BATTERY POS. (+)
EXTEND WIRE AND CONNECT TO BATTERY NEG. (-)
Page 10 of 16
CLUB CAR WIRING HARNESS with ON BOARD DELTA-Q BATTERY CHARGER - DIAGRAM 2.5 FORWARD/ REVERSE SWITCH
WHITE RED-YELLOW
SEE DIAGRAM 2.7
RED-YELLOW BLUE
YELLOW PURPLE BLUE 6 PIN PLUG TO MOTOR ENCODER
PARK SWITCH
BRAKE SWITCH
BLUE GREEN BLACK/ WHITE PURPLE/ WHITE
35 PIN CONNECTOR
THROTTLE CONNECTIONS
YELLOW/ WHITE WIRE BUNDLE
YELLOW GRAY DASH PANNEL SEE DIAGRAM 2.8
BLUE BROWN ORANGE RED WHITE/ RED
FUSE 10A
8 PIN DISPLAY PLUG
GREEN TO BATTERY POS (+) #2 CABLE BLUE/ WHITE
+ Main Contactor
TO CONTROLLER POS (+) MAIN FUSE #2 CABLE
WHITE
BLACK - HOT
BLACK
-
RED
ORANGE/ WHITE
WHITE - NEUTRAL GREEN - GROUND
110 VOLT AC PLUG
TO BATTERY NEG. (-) TO BATTERY POS. (+)
Page 11 of 16
FORWARD/ REVERSE SWITCH DETAIL
- DIAGRAM 2.6
WHITE 1
4
2
5
3
6
RED/ YELLOW YELLOW
Page 12 of 16
CLUB CAR DASH PANEL WIRING DETAIL - DIAGRAM 2.8 YELLOW
REVERSE BUZZER
1
GRAY BROWN
2
ORANGE BLUE
BLUE
GOLF / STREET SWITCH
KEY SWITCH
ORANGE
RED
BLUE
BROWN (FROM CHARGE CONTROLLER IF USED)
TO BRAKE LIGHTS
CHARGE LIGHT 87
BLUE
WHITE / RED
86
85
MENU
BDI CABLE
30
DASH DISPLAY
+12V IN
BRAKE LIGHT RELAY
Page 13 of 16
REVISIONS
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.
87
86
RED/ YELLOW 18AWG
4 5 6 7 8 9 10 11 12 14 16 17 18 19 20
24 25
29 30 31 32 33 34 35
ORANGE/ WHITE18 AWG
I/O GROUND
BLACK/ BLUE 18 AWG
MOTOR TEMP SENSOR
YELLOW/ BLACK 18 AWG
PEDAL INTERLOCK
GREEN 18 AWG
MENU BUTTON
WHITE/ RED 18 AWG
BRAKE SWITCH
PURPLE 18 AWG
GOLF / STREET SWITCH
BROWN 18 AWG
COIL RETURN
BLUE/ WHITE 18 AWG
BLUE 18AWG
MENU BUTTON (NOTE *3)
BRAKE SWITCH (NOTE *6)
BLUE 18AWG
MAIN CONTACTOR (NOTE *4)
N/C POT HIGH
BLACK/ WHITE 18 AWG
POT WIPER
YELLOW/ WHITE 18 AWG
R3 1
N/C
2
POT HIGH
POT LOW
DEUTSCH DT-06-2S
B
PURPLE/ WHITE 18 AWG
POT WIPER
N/C
THROTTLE MODULE
A POT LOW
N/C
C
N/C
R2
FOWARD
DEUTSCH DT-06-3S
WHITE 18 AWG
N/C
S1
N/C 12V POWER CNTRL
RED/ BLUE 18 AWG
5V POWER CNTRL
RED/WHITE 18 AWG
I/O GROUND
BLACK/ BLUE 18 AWG
TX SERIAL
GREY/ BLUE 18AWG
12V POWER CNTRL
RED/ BLUE 18 AWG
8 6
DISPLAY 5
N/C TX SERIAL
GREY/ BLUE 18AWG
RX SERIAL
GREEN/ WHITE 18 AWG
RX SERIAL
GREEN/ WHITE 18 AWG
ENCODER PHASE A
TAN/BLACK 18 AWG
ENCODER PHASE B
TAN 18 AWG
REVERSE
YELLOW 18 AWG
N/C
P4
(*1) BLACK AND WHITE NOT USED ON 2 WIRE POT. SELECT TYPE 3 PARAMETER.
BLACK/ BLUE 18 AWG
(*2) NORMALLY CLOSED SWITCH. OPEN FOR PARK. IF SWITCH NOT USED, RED/YELLOW WIRE IS CONNECTED TO BLUE.
TAN 18 AWG
(*3) MENU BUTTON IS OPTIONAL USE WITH DISPLAY. NORMALLY OPEN; MOMENTARY
TAN/ BLACK 18 AWG BLACK/ BLUE 18 AWG
(*4) REMOVE ANY DIODES OR RESISTOR FROM MAIN CONTACTOR.
(*7) MOTOR TEMP SENSOR NOT USED FOR GOLF CART APPLICATION. (*8) SPLICE S4 TO BE PERFORMED BY THE END USER.
R5
DEUTSCH DTM-04-6P RED/ WHITE 18 AWG
(*6) NORMALLY CLOSED. CONTACTS MUST BE CLOSED WHEN BRAKE PEDAL IS PRESSED; OPEN WHEN BRAKE PEDAL IS NOT PRESSED.
1
R6
NOTES:
(*5) USE 400A FUSE IN 650 SYSTEM. USE 300A FUSE IN 350 SYSTEM.
400A (NOTE *5)
MOLEX MINI FIT JR 39-01-2080 Note: Pins 2, 3, 4, & 7 are not connected
N/C
N/C
-
+
GOLF / STREET SWITCH
U
28
MAIN CONTACTOR COIL
S2
V
27
10A
N/C
W
26
BACK UP BUZZER
35 PIN CONNECTOR (SEE R1)
23
GRAY 18 AWG
B+
22
ORANGE 18 AWG
BACK UP BUZZER
11/15/2011
+48V OR 72V
B-
21
S4 (NOTE *8)
BLUE 18AWG
-A2
15
BLUE 18AWG
+A1
13
KSI
N/C BRAKE RELAY
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 title block. M issing dimensions were addded
S3
YELLOW/ BLACK 18 AWG
1
1
2
2
3
3
4
4
5
5
6
6
MOLEX SL SERIES 50-57-9405
MOTOR ENCODER CABLE RED/ WHITE 22 AWG BLACK/ BLUE 22 AWG TAN 22AWG TAN/ BLACK 22 AWG BLACK 22 AWG
2 3 4 5
PURPLE 22 AWG
R4 DEUTSCH DTM-06-6S
W
V
U
1 N/C
MOTOR ENCODER
3
Added R2 & R3 connectors
BLUE 18AWG
PARK SWITCH (NOTE *2)
BLUE 18 AWG
KSI
B RED 18AWG
REVERSE
FORWARD / REVERSE SWITCH
APPROVED
INITIAL RELEASE
FOWARD 85
DESCRIPTION
A
12V IN
R1
2
BLUE 18AWG
BLUE 18AWG
AMP 776164-1
1
KEY SWITCH
30
TO BRAKE LIGHTS
BRAKE LIGHTS RELAY
REV ORIGINATOR
MOTOR TEMP SENSOR (NOTE *7)
MOTOR
CAD TYPE VISIO OPER. NO.
CAD LOC.
CAD FILE
UNIT
DRAWING
DESIGN
DETAIL
TITTLE
CHECKED
SAFETY
SCALE NONE
DATE 12/29/10
DRW SIZE B
1010-CLUBCAR-001 CLUB CAR SYSTEM SCHEMATICS
REVISION E SHEET 1 OF
1
HPEV SYSTEM WIRING DETAIL - DIAGRAM 2.9 Page 14 of 16
HPEVS
HIGH CURRENT WIRING DETAIL - DIAGRAM 2.10
35 PIN CONNECTOR
Main Contactor
CONTROLLER
V
U
W
+
-
BLUE/ WHITE B+
ORANGE/ WHITE
B-
FUSE
FRONT OF CART
6 PIN
TO WIRING HARNESS
U V W
MOTOR
Page 15 of 16
PICTURE 1.1
PICTURE 1.2
PICTURE 1.3
PICTURE 2.1
PICTURE 2.2
CONTROLLER MOUNTING Page 16 of 16
