INSTALLATION INSTRUCTIONS Club Car DS Installation Notes · 620 Magnolia Avenue Suite B Ontario, CA 91762 (909)923-1973. INSTALLATION INSTRUCTIONS Club Car . DS Installation Notes.

620 Magnolia Avenue Suite B

Ontario, CA 91762 (909) 923-1973

INSTALLATION INSTRUCTIONS

Club Car DS Installation Notes

CURTIS 1232, 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

Page 3 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 4 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 5 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 6 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 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.

Page 7 of 16

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

Page 12 of 16

FORWARD/ REVERSE SWITCH DETAIL - DIAGRAM 2.6

4

5

6

1

2

3

WHITE

RED/ YELLOW

YELLOW

Page 13 of 16

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

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.

VISIO

12/29/10

31 G

1010-CLUBCAR-001

CLUB CAR DS SCHEMATIC

NONE

ORANGE/ WHITE 20 AWG

PEDAL INTERLOCK

MENU BUTTON

POT WIPER

FOWARD

12V POWER CNTRL

5V POWER CNTRL

TX SERIAL

RX SERIAL

ENCODER PHASE A

ENCODER PHASE B

REVERSE

KSI

MAIN CONTACTOR COIL

COIL RETURN

BLUE 20 AWG

GREEN 20 AWG

WHITE/ RED 20 AWG

BLUE/ WHITE 20 AWG

YELLOW/ WHITE 20 AWG

YELLOW 20 AWG

RED / BLUE 20 AWG

RED / WHITE 20 AWG

GREY/ BLUE 20 AWG

GREEN/ WHITE 20 AWG

TAN 20 AWG

TAN/ BLACK 20 AWG

WHITE 20 AWG

MOTOR TEMP

GOLF / STREET SWITCH

MENU BUTTON (NOTE *3)

YELLOW/ BLACK 20 AWG

PARK SWITCH (NOTE*2)

POT HIGH BLACK/ WHITE 20 AWG

POT LOW PURPLE/ WHITE 20 AWG

R6MOLEX MINI FIT JR 39-01-2080

10A

BRAKE SWITCH

BROWN 20 AWG

KEY SWITCH

A B

OFF

ON

BRAKE RELAY

ECONOMY MODE

S1

BACK UP BUZZER

R1 AMP

#776164-1

UVW

B +B -

35 PIN

CO

NN

ECTO

R

(SEE R1)

A

B

+ -

U

MOTOR

MO

TOR

EN

CO

DER

A

1:1

W

V

+A1 -A2 87 30

85 86

ORANGE 20 AWG

TO BRAKE LIGHTS + 12 V

BACK UP BUZZERGRAY 20 AWG

S2

PURPLE 20 AWG

MOTOR TEMP SENSOR

BRAKE SWITCH (NOTE*6)

400A (NOTE *5)DISPLAY

6

5

8

1

R2DEUTSCH DT-06-3S

R3DEUTSCH DT-06-2S

C

A

B

21

THROTTLE POT

YELLOW/REDFORWARD

REVERSE

NOTES:

(*1) DELETED NOTE

(*2) NORMALLY CLOSED SWITCH. OPEN FOR PARK. IF SWITCH NOT USED, RED/YELLOW WIRE IS CONNECTED TO RED/BLUE WIRE.

(*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.

P4DEUTSCH

DTM-04-4P

1

2

1

2

3

4

P4BDEUTSCH

DTM-04-2P

DRW SIZE

APPLICABLE SOFTWARE

CAD TYPE

UNIT DRAWING

TITLE

SCALE

DATE

REVISIONSHEET HPEVSOF

SUPPLIER PART HW-2010-HPG

S3

S5

S4

1

3

4

6

7

10

11

12

13

15

16

22

25

26

28

29

31

32

33

8

9

I/O GROUND BLACK/ BLUE 20 AWG

18

REV DESCRIPTION APPROVED

G

Wire gauge change f rom 18 t o 20 awg.Splices S3 and S4 were moved f rom Blue wire t o red/ blue wire.Added S5 splice on Red/ Blue wire.Added red/ blue wires f rom S4 splice t o F8 and F9 wit h 1/ 4" QD f emaleChange wires color f rom blue t o red/ blue at E3 & E4Rename P4-2 connect or t o P4B

8/ 31/ 2017

REVISIONS

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