1551 S. Vineyard Avenue Ontario, CA 91761

(909) 923-1973

INSTALLATION INSTRUCTIONS

E-Z-GO Installation Notes

CURTIS 1234, 1236 OR 1238

AC INDUCTION MOTOR/ CONTROLLER

Page 2 of 20

EZ-GO Curtis Controller Installation

1. Disconnect Negative Battery Cable, Disconnect Positive Battery Cable.

2. Disconnect all Motor and Controller wires.

3. Remove original Motor, Controller & Reversing Switch (remove controller-mounting plate, if equipped).

4. Remove original wiring harness. Unplug any connector’s possible (cut as little as possible). If equipped with rear brake lights, label and keep factory wires from the brake pedal switch. These wires will be reused to enable the brake lights. (See DIAGRAM 2.1)

5. Install the Controller mounting plate in cart. See PICTURE 1.5. Installation of the cables and wiring harness will be outlined in later steps.

6. Bolt the Controller, ITS Converter & Solenoid to new mounting plate. Use supplied ¼-20 bolts and lock washers.

7. Install new AC 9 Motor. Use the supplied ¼-20 bolts and lock washers. Do not over torque Motor Bolts.

8. 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. This procedure is not needed if cart has been lifted. Not required if the cart is lifted.

9. If equipped, install the on-board Battery Charger. For Delta-Q Battery Charger see Picture 1.6 and DIAGRAM 2.4 for reference.

10. 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 Picture 1.7 and DIAGRAM 2.8 for reference.

11. Connect one side of the solenoid to the Fuse Post on the Controller.

12. Connect Negative Battery Cable to the controller. (DO NOT connect to Battery at this point).

Page 3 of 20

13. Install Wiring Harness. Refer to DIAGRAM 2.7

14. Use supplied cable adapter for throttle wires. Plug the flat connector into the ITS converter box. Plug 4-pin square connector into mating connector on wiring harness. Connect the Blue wire to the Blue wire on the solenoid, Red to the Red, Green to the Green, White to the White & Black to the Black on the ITS cable.

15. Connect wires to FWD/REV switch, See DIAGRAM 2.5 & 2.6. Connect the Blue wire to the center connector tab. Connect the Yellow towards “F”, forward and White towards “R”, reverse.

16. Drill a 2 1/16” hole in the dash panel for the BDI.

17. Plug cable with 8-pin connector into the back of the Dash Display.

18. Connect Red Wire to one side of Key switch.

19. Connect Blue wire to key switch.

20. Connect a Yellow wire from F & R switch to the positive side of the reverse buzzer, and the Gray wire to the negative. See DIAGRAM 2.6.

21. 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 2.6 & 2.7 .

2 2 . 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 #4. The below connections can be reviewed by using the DIAGRAMS 2 . 2 , 2 . 3 & 2 . 7 22.1. Connect the factory +12V source Red wire to the relay at terminal #30. 22.2. Connect the factory Brown wire of the rear brake lights to the Brake

Relay at terminal #87. Wire color may be different depending on model year.

22.3. Connect a Blue wire from the key switch to the Brake Relay at terminal #86.

22.4. Connect the Orange wire to the Brake Relay at terminal #85.

Page 4 of 20

22.5. Connect Blue wire to the COM on the Brake Switch, Connect the purple wire to the N.C. terminal.

23. Connect White/Red wire to Menu Button. Connect other side of button to Blue wire on the key switch. See DIAGRAM 2.6.

24. Connect Orange/White wire to the – (negative side of the Main Contactor), and Blue/White wire to the + (positive side). Remove any diode, resistors.

25. Connect Fuse Wire and the + Battery cable to the Main Contactor. If On Board charger is used, connect fuse wire to the Green wire from the charger.

26. Plug in Encoder Cable to the motor.

27. DOUBLE CHECK ALL CONNECTIONS.

28. Secure all wires, harnesses and cables to the cart’s frame by using tie straps.

29. Install 10 Amp fuse at the fuse holder in the system harness.

30. Connect – (negative) Battery Cable.

31. Test Cart on Jack Stands. There will be no motor damage if the motor initially over speed. If motor runs slow and in the wrong direction, reverse the U and W leads on the Motor.

Page 5 of 20

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 Gauge), 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)

GOLF Cart in Golf Mode (see note below)

REVERSE Cart in Reverse direction (see note below)

LOWBATT Cart in Limp Home mode (see note below)

Menu System:

Battery Percentage: State of Charge left in batteries.

TOC: Time on Charge, Time in minutes since the last time the car was charged.

Volts: Battery Voltage

RPM: Motor RPM

The last menu option is the vehicle odometer.

Street Mode gives the cart 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 is also reduced.

Page 6 of 20

Drive Mode can be changed on “The Fly”. There is no need to stop the cart 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 is 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 20

Instructions for Throttle Set Up

For systems set up after March 2007 with Version 8.00U software

With Key OFF, Select Forward Direction, Release Parking Brake, Press and hold the “Menu” Button, then turn the Key “ON”. Hold Menu Button until “Program” appears on the Dash Display, then release.

If the cart has a brake pedal switch:

Use the Brake Pedal to cycle through the options. Have the Golf/Street Mode switch set to “Street Mode”, (MPH), to change parameters.

If the cart does not have a brake pedal switch:

Select “Golf Mode” and press the “Menu Button” to cycle through the options.

To change a parameter in any of the options:

Select “Street Mode” and press the “Menu Button” to change a parameter or activate an option.

T Type: This is the Throttle Pot Type Parameter. For 0-to-5k, 2-wire throttle pots, set to type 3. For 3-wire throttle pots or EZ Go with ITS converter box, set to Type 2. The default is Type 2.

Throttle: This allows the Throttle range to be calibrated.

Cycle the program options to “Throttle” on the Dash Display, select Street Mode, press the Accelerator Pedal to the floor (Max Throttle).

With the pedal pressed, press and hold the “Menu” Button and the display will show “HoldMenu”. Maintain the pedal and menu button pressed until the display reads “Turn OFF”. After this message is displayed, turn off the Key. DO NOT release the accelerator pedal or the Menu button before turning OFF the Key. The Throttle is now calibrated.

Using this procedure will ensure full throttle range; if this procedure is not performed the calibration will be at to a default setting. Use this set up procedure for 2-wire, 0-to-5k, three wire throttle or EZ Go with ITS converter box types.

Page 8 of 20

Rst: This is the BDI reset voltage per battery cell. Adjust only if there is a problem with the BDI resetting to 100% when the batteries are below 85% and have not been charged or not resetting after a charge.

To increase the parameter, select “Forward” and “Street Mode”, then press the Menu button.

To decrease, select “Reverse” and “Street Mode”, then press the Menu button. The default is 2.125 volts per cell; this should work fine in most applications.

Mode: Sets the Motor Control Mode. The control mode can be set as Mode 1 or Mode 2

Mode 1 is Speed Control. Speed Control means the accelerator pedal controls the actual speed of the vehicle.

For example: In Speed Control Mode if you set the accelerator pedal to half, you will go half speed, uphill, downhill or on flat ground. Speed Mode is great if you are looking for controlled descents down hills and want to use the brakes a little as possible. It does however have more of a jerky feel when changing speeds with the accelerator pedal.

Mode 2 is Torque Control Mode. Torque control is the same type of control method a DC motor has. The accelerator pedal controls the amount of torque the motor produces. This gives a much smoother feel when changing the accelerator position. Brakes will be used more in downhill descents.

Brk%: Only available if the Speed Mode is set to “2”. This sets the amount of Regen when the Brake Pedal is pressed.

To increase the parameter, select “Forward” and “Street Mode”, then press the Menu button. To decrease, select “Reverse” and “Street Mode”, then press the Menu button.

If the default braking level is desired, leave this set to Zero. The Default is 40%. So, setting to 1% would be the lowest setting and give almost no Regen.

Page 9 of 20

Instructions for using On Board Diagnostics

With the Key OFF, Select Reverse Direction, Press and hold the “Menu” Button. Turn Key the “ON”, hold Menu Button until “Diagnose” appears on the Dash Display, then release the Menu Button. Pressing and releasing the menu button will scroll through the Diagnostic options. The cart can be driven during diagnostic checks.

T Sw: This monitors the state of the Throttle Switch. With the pedal in the idle position the display should read “OFF”, when the pedal is pressed the display should change to “ON”. If “OFF” is always displayed there is a problem with the switch on the throttle pedal. This test can be performed in “Neutral” or with either direction selected.

TPV: This is the raw Throttle pot voltage. This test should be performed with the car in “Neutral”. 0.2 volts is normal for idle position, at full throttle, 3.5 volts for 2 wire pots, and 5.0 volts for 3 wire pots.

T Max: This is what the Max Throttle Voltage Parameter is set at. For example: If the Parameter is set at 4.5, then the TPV will need to reach 4.5 for full speed to be obtained. Use the Throttle calibration procedure if adjustments are necessary.

Req %: This is the amount of throttle being requested of the controller. This should be a number from 0 to 100% when the car is being driven.

Brk: On or Off. Checks to ensure brake switch signal input to the controller. Should be ON when the brake pedal is pressed and OFF when the brake pedal is released.

Page 10 of 20

CapV: This is the voltage on the Capacitor Bank inside the controller. This voltage should be at or near the voltage of the Batteries. When the Throttle is pressed, this sends a signal to the controller to pre-charge the Capacitor Bank and turn the Main Solenoid ON. If this voltage is low or at 0, this means there is probably a failure in the Pre-Charge circuit and the controller will need to be repaired or replaced.

EncA & EncB: These are the Motor Encoder signals shown in RPM. This can be used to troubleshoot either an Encoder failure, or a problem in the Encoder wiring. If the motor turns slow and in the proper direction, check the RPM of both signals. If EncA has no signal, the Display will read Zero. The same applies to EncB. EncA involves with White, (sometimes Brown), wire on the encoder connector, EncB is the Green wire. On an EZGO, these colors are reversed.

Main: This is the state of the Main Contactor, see table below:

0 = Open, Solenoid not turned on.

1 = Pre-charge.

2 = Weld check, the controller is checking for welded contacts.

3 = Closing Delay

5 = Closed, the Solenoid coil is energized and the contacts should be closed.

6 = Open Delay, after the cart is stopped there is a delay of about 5 seconds for the Solenoid to open.

OS: This is the Version of the Operating System in the controller.

Build: This is the Build number of the Operating System.

Ver: This is the VCL (vehicle control language) version number.

D/C: This is the date when the controller was manufactured. 6123=the 123rd day of 2006

Page 11 of 20

S/N: This is the unique serial number of the controller.

Faults: If any, will be displayed.

Fault Codes

Fault codes will display on the Dash Display when they happen, the “Wrench” on the display will also light up.

Code 12, Controller Over Current

Code 13, Current sensor fault

Code 14, Precharge Failure

Code 16, Controller Over Temperature

Code 17, Severe Undervoltage

Code 18, Severe Overvoltage

Code 25, 5-volt power supply failure

Code 36, Encoder Fault, see diagnose, EncA & EncB.

Code 37, Motor Open or Open Phase on controller fault

Code 38, Main Solenoid welded

Code 39, Main Solenoid not closing

Code 73, Stall detected, No encoder signal, see diagnose, EncA & EncB.

Page 12 of 20

Picture 1.5

Picture 1.6

Picture 1.7

Page 13 of 20

EZ-GO FACTORY BRAKE LIGHT KIT WIRING DETAIL

-DIAGRAM 2.1

TO FACTORY

BRAKE LIGHT

FROM +12V

BATTERY

RED

BROWN

BRAKE PEDAL

BRAKE SWITCH

Page 14 of 20

HPEV AC-9 SYSTEM BRAKE LIGHT WIRING DETAIL

-DIAGRAM 2.2

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

PURPLE

BRAKE SWITCH

WIRING DETAIL

BRAKE PEDAL

BROWN

Page 15 of 20

BRAKE LIGHT REWIRING RELAY DETAIL

-DIAGRAM 2.3

85

87

86

30

BRAKE LIGHT

RELAY

TO FACTORY

BRAKE LIGHTS

BLUE

FROM +12V

BATTERY

BROWN

ORANGE

FROM HPEV

SYSTEM

HARNESS

FROM HPEV

SYSTEM

HARNESS

RED

Page 16 of 20

EZ-GO WIRING HARNESS with ON BOARD DELTA -Q BATTERY CHARGER -

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 2.5

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 2.6

GREEN

RE

D

BL

AC

K

WH

ITE

TO BATTERY NEG. (-)

TO BATTERY POS. (+)

WHITE - NEUTRAL

BLACK - HOT

GREEN - GROUND

110 VOLT AC

PLUG

RED

Page 17 of 20

FORWARD/ REVERSE SWITCH DETAIL - DIAGRAM 2.5

WHITE

BLUE

YELLOW

FWD

REV

Page 18 of 20

1

2

EZ-GO DASH PANEL WIRING DETAIL - DIAGRAM 2.6

DASH

DISPLAY

REVERSE

BUZZER

KEY

SWITCH

MENU

BUTTON

BLUE

YELLOW

GRAY

BROWN

RED

WHITE / RED

BDI CABLE

FWD

REV

BLUE

GOLF/

STREET

SWITCH

WHITE

FORWARD/

REVERSE

SWITCH

YELLOW

BLUE

BLUE

Page 19 of 20

VISIO

12/21/10 1 1

85 86

87 30

BRAKE

LIGHTS

RELAY

1010-EZ-GO

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

EZ-GO GOLF CART

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

RED 18AWG

+48V OR 72V

TO BRAKE LIGHTS

BRAKE SWITCH

(NOTE *5)

S2

R3MOLEX MINI FIT JR

39-01-2080

Note: Pins 2, 3, 4, &

7 are not connected

BLUE 18AWG

KEY SWITCH

10A

MENU BUTTON

(NOTE *2)

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 (NOTE *1)

MAIN

CONTACTOR

(NOTE *3)

+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

BLUE 18AWG

BLUE 18AWG

NOTES:

(*1) IF REVERSE IS NOT USED, CONNECT WHITE WIRE TO BLUE WIRE.

(*2) MENU BUTTON IS OPTIONAL USE WITH DISPLAY.

(*3) REMOVE ANY DIODES OR RESISTOR FROM MAIN CONTACTOR.

(*4) USE 400A FUSE IN 650 SYSTEM. USE 300A FUSE IN 350 SYSTEM.

(*5) NORMALLY OPEN. CONTACTS MUST BE CLOSED WHEN BRAKE PEDAL

IS PRESSED.

(*6) MOTOR TEMP SENSOR NOT USED FOR GOLF CART APPLICATION.

POT WIPER

POT HIGH

MOTOR ENCODER

CABLE

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 *6)

N/C

12V IN

C

BLUE 18AWG

YELLOW 18 AWG

WHITE 18 AWG

4

3

2

1

P2MOLEX

MINI FIT JR

39-01-2041

N/C

I/O GROUND

PEDAL INTERLOCK

BLACK/ BLUE 18 AWG

YELLOW/ WHITE 18 AWG

BLACK/ WHITE 18 AWG

GREEN 18 AWG

BLACK/ BLUE 18 AWG

GREY/ BLUE 18AWG

RED/ BLUE 18 AWG

GREEN/ WHITE 18 AWG

400A

(NOTE *4)

YELLOW 18 AWG

R2MOLEX

MINI FIT JR

39-01-2040

4

3

2

1

WHITE 18 AWG

RED 18 AWG

BLUE 18 AWG

BLACK 18 AWG

GREEN 18 AWG

ITS

CO

NV

ER

TE

R

4

3

2

1

ITS1

2

3

4

5

6

BLUE/ WHITE 18 AWG

ORANGE/ WHITE18 AWG

WHITE 18 AWG

BLACK 18 AWG

BLUE 18 AWG

ITS

THROTTLE

UNIT

BLACK/ BLUE 22 AWG

RED/ WHITE 22 AWG

TAN 22AWG

TAN/ BLACK 22 AWG

YELLOW/ BLACK 18 AWG

BLACK/ BLUE 18 AWG

BLACK/ BLUE 18 AWG

TAN 18 AWG

TAN/ BLACK 18 AWG

RED/ WHITE 18 AWG

REV ORIGINATOR DESCRIPTION APPROVED

C

M AJOR REVISION; M ISSING

DIM ENSIONING WERE ADDED 11/17/2011

REVISIONS

HPEVS SYSTEM WIRING DETAIL - DIAGRAM 2.7

Page 20 of 20

U V W

B + B -FUSE

CONTROLLER

MOTOR

35

PIN

CO

NN

EC

TO

R

Main

Contactor

BLUE/ WHITE

ORANGE/ WHITE

+ -

6 PIN

TO WIRING

HARNESS

U

W

V

FRONT OF

CART

HIGH CURRENT WIRING DETAIL - DIAGRAM 2.8