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 (COMMON) RED/ YELLOW (Normally Closed) PARK SWITCH PARK SWITCH WIRING DETAIL NORMALLY CLOSED NORMALLY CLOSED NORMALLY OPEN NORMALLY OPEN COMMON RED / YELLOW COMMON PURPLE BRAKE SWITCH WIRING DETAIL PURPLE (Normally Closed) BRAKE SWITCH (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 TO FACTORY BRAKE LIGHTS RED ORANGE FROM HPEVS SYSTEM HARNESS FROM HPEVS SYSTEM HARNESS 86 87 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 YELLOW RED-YELLOW PARK SWITCH 6 PIN PLUG TO MOTOR ENCODER PURPLE BRAKE SWITCH 35 PIN CONNECTOR WIRE BUNDLE GREEN BLACK/ WHITE PURPLE/ WHITE YELLOW/ WHITE THROTTLE CONNECTIONS YELLOW GRAY DASH PANEL BROWN SEE DIAGRAM 2.8 ORANGE RED FUSE 10A / WHITE + Main Contactor YELLOW (NOT USED) RED TO BATTERY POS (+) #2 CABLE 10 GAUGE BLACK GRAY BROWN CHARGER PLUG WHITE/ RED 8 PIN DISPLAY PLUG BROWN FORM ORIGINAL CHARGE COMPUTER IF USED ORANGE/ WHITE - 10 GAUGE BLACK HOLE IN CHARGE COMPUTER TO BATTERY POS. (+) TO CONTROLLER POS (+) MAIN FUSE #2 CABLE 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 SEE DIAGRAM 2.7 WHITE RED-YELLOW YELLOW RED-YELLOW PARK SWITCH 35 PIN CONNECTOR 6 PIN PLUG TO MOTOR ENCODER WIRE BUNDLE PURPLE GREEN BLACK/ WHITE PURPLE/ WHITE YELLOW/ WHITE BRAKE SWITCH THROTTLE CONNECTIONS YELLOW GRAY BROWN ORANGE RED DASH PANNEL SEE DIAGRAM 2.8 FUSE 10A WHITE/ RED GREEN 8 PIN DISPLAY PLUG / WHITE + TO BATTERY POS (+) #2 CABLE ORANGE/ WHITE - Main Contactor RED BLACK WHITE BLACK - HOT WHITE - NEUTRAL GREEN - GROUND 110 VOLT AC PLUG TO CONTROLLER POS (+) MAIN FUSE #2 CABLE TO BATTERY NEG. (-) TO BATTERY POS. (+) Page 11 of 16
FORWARD/ REVERSE SWITCH DETAIL - DIAGRAM 2.6 WHITE RED/ YELLOW YELLOW 1 2 3 4 5 6 Page 12 of 16
CLUB CAR DASH PANEL WIRING DETAIL - DIAGRAM 2.8 YELLOW GRAY REVERSE BUZZER 1 BROWN 2 ORANGE RED KEY SWITCH GOLF / STREET SWITCH ORANGE BROWN (FROM CHARGE CONTROLLER IF USED) CHARGE LIGHT TO BRAKE LIGHTS WHITE / RED BDI CABLE MENU 86 87 85 30 DASH DISPLAY +12V IN BRAKE LIGHT RELAY Page 13 of 16
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. KEY SWITCH REVISIONS REV ORIGINATOR DESCRIPTION APPROVED A INITIAL RELEASE R1 AMP 776164-1 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 KSI BRAKE RELAY BACK UP BUZZER MAIN CONTACTOR COIL I/O GROUND MOTOR TEMP SENSOR PEDAL INTERLOCK MENU BUTTON BRAKE SWITCH GOLF / STREET SWITCH COIL RETURN POT HIGH POT WIPER POT LOW FOWARD 12V POWER CNTRL 5V POWER CNTRL TX SERIAL RX SERIAL ENCODER PHASE A ENCODER PHASE B REVERSE NOTES: TO BRAKE LIGHTS 18 AWG ORANGE 18 AWG GRAY 18 AWG PURPLE 18 AWG BRAKE LIGHTS RELAY ORANGE/ WHITE18 AWG BLACK/ 18 AWG YELLOW/ BLACK 18 AWG GREEN 18 AWG WHITE/ RED 18 AWG BROWN 18 AWG / WHITE 18 AWG BLACK/ WHITE 18 AWG YELLOW/ WHITE 18 AWG PURPLE/ WHITE 18 AWG WHITE 18 AWG RED/ 18 AWG RED/WHITE 18 AWG GREY/ 18AWG GREEN/ WHITE 18 AWG TAN/BLACK 18 AWG TAN 18 AWG YELLOW 18 AWG 87 30 85 86 (*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. (*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. 12V IN S1 S2 FOWARD REVERSE FORWARD / REVERSE SWITCH BACK UP BUZZER POT HIGH POT WIPER POT LOW RED/ WHITE 18 AWG BLACK/ 18 AWG TAN 18 AWG TAN/ BLACK 18 AWG BLACK/ 18 AWG YELLOW/ BLACK 18 AWG I/O GROUND TX SERIAL 12V POWER CNTRL RX SERIAL P4 DEUTSCH DTM-04-6P 1 2 3 4 5 6 1 2 3 4 5 6 R4 DEUTSCH DTM-06-6S RED/ YELLOW 18AWG B A C R2 DEUTSCH DT-06-3S KSI MOTOR ENCODER CABLE RED/ WHITE 22 AWG BLACK/ 22 AWG TAN 22AWG TAN/ BLACK 22 AWG BLACK 22 AWG PURPLE 22 AWG 18AWG 1 PARK SWITCH (NOTE *2) 2 THROTTLE MODULE 18AWG BLACK/ 18 AWG GREY/ 18AWG RED/ 18 AWG R3 DEUTSCH DT-06-2S GREEN/ WHITE 18 AWG R6 MOLEX MINI FIT JR 39-01-2080 Note: Pins 2, 3, 4, & 7 are not connected 8 6 5 1 18AWG BRAKE SWITCH (NOTE *6) DISPLAY R5 MOLEX SL SERIES 50-57-9405 1 2 3 4 5 MOTOR ENCODER MOTOR TEMP SENSOR (NOTE *7) S3 W V U MOTOR 18AWG MENU BUTTON (NOTE *3) GOLF / STREET SWITCH 18AWG 18AWG 18AWG HPEV SYSTEM WIRING DETAIL - DIAGRAM 2.9 CAD TYPE CAD LOC. CAD FILE VISIO OPER. NO. UNIT DRAWING DESIGN S4 (NOTE *8) 35 PIN CONNECTOR (SEE R1) CHECKED 10A +A1 -A2 DETAIL SAFETY RED 18AWG +48V OR 72V W MAIN CONTACTOR (NOTE *4) B - B + V TITTLE U SCALE DATE REVISION E NONE 12/29/10 SHEET 1 OF 1 B E + - 400A (NOTE *5) Added R2 & R3 connectors 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 11/15/2011 1010-CLUBCAR-001 CLUB CAR SYSTEM SCHEMATICS Page 14 of 16 DRW SIZE B HPEVS
HIGH CURRENT WIRING DETAIL - DIAGRAM 2.10 CONTROLLER U V W 35 PIN CONNECTOR Main Contactor + - / WHITE FUSE B + B - ORANGE/ WHITE 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