MASTERFLUX GOLF CART 48V AIR-CONDITIONER AND HEAT PUMP

INSTALLATION MANUAL

CLUB CAR DS Electric Model

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HAZARDOUS MATERIAL WARNING! BATTERY- EXPLOSION HAZARD. Do not smoke while near vehicle while it is being serviced! Keep sparks and flames away from vehicle when servicing. Service only in well ventilated area. BATTERY- POISON. Contain acid- causes severe burns! Avoid contact with skin, eyes of clothing. Battery acid can cause blindness- wear full-face shield and rubber gloves while working with or near batteries. If contact occurs:

External- Flush with Water. Call Physician immediately. Internal- Drink large quantities of milk or water followed by Milk of Magnesia or vegetable oil.

Call Physician immediately after ingestion. Eyes- Flush with water for 15 minutes. Call Physician immediately.

Battery is to be disconnected while installation is performed. CAUTION! To be serviced only by technicians trained in mechanical or electrical repair. Technician must use appropriate instructions, including this Installation Guide when servicing this unit. Installation Guide instructions are to be followed exactly. Heed all CAUTION, WARNING and DANGER statements given in this Guide as well as those posted on the vehicle and unit. Before servicing vehicle, turn key switch to OFF and set parking brake. Wear safety glasses when servicing vehicle. Do not service vehicle when it is running. Allow motor to cool before serving vehicle. Servicing vehicle when motor is HOT can result is Severe Burns. Insulated tools should be used when working near batteries or electrical connections. Failure to do so could result in dangerous and damaging electrical shorts. Make sure wiring and wiring harness are properly routed and secured. Failure to properly route and secure wiring could result in vehicle malfunction, property damage, personal injury or death.

TOOLS REQUIRED FOR INSTALLATION PHILLIPS HEAD SCREW DRIVER 7/16 OPEN END WRENCH 1/2 “ OPEN END WRENCH 1/2” SOCKET 7/16” SOCKET RATCHET PLIERS WIRE CUTTERS BOLT CUTTERS OTHER TOOL SUITABLE FOR CUTTING THROUGH ¼ INCH BOLT WIRE CRIMPING TOOL DRILL WITH 1“ HOLE CUTTER (OPTIONAL)

STANDARD PARTS

48V AIR-CONDITIONING- (P/N CRS0000480) OR AIR-CONDITIONING/HEAT PUMP UNIT- (P/N CRS0000485)

DS MOUNTING KIT P/N LP183 o KIT CONSISTS OF:

BASKET

REAR OF CART

SIDE SUPPORT BRACKETS

BAG SUPPORT BRACKET

FRONT OF CART

BASKET CONDENSER UNIT MOUNTING BRACKET- RIGHT CONDENSER UNIT MOUNTING BRACKET- LEFT

FRONT OF CART

LEFT CONDENSER MOUNTING BRACKET

RIGHT CONDENSER MOUNTING BRACKET

ID STAMP

CONDENSER UNIT MOUNTING BRACKETS 71481 REV-REL (4/26/06)

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CONDUIT/FLEX LINE MOUNTING BRACKET

SLOTS FOR MOUNTING TO REAR ROOF SUPPORT

REAR OF CART

HOLE FOR MOUNTING TO EVAPORATOR BRACKET

HOLE FOR QUICK TIE

FLEX LINE MOUNTING BRACKET EVAPORATOR MOUNTING BRACKET-SHOWN BELOW SIDE FLANGES

FACING UPWARD.

½” FLANGELEFT SIDE MOUNTING HOLES FRONT OF CART ACCESS

HOLES

PEM NUT FOR MOUNTING FLEX LINE BRACKET

REAR OF CART-KNOB AND NOZZLES OF EVAPORATOR UNIT

EVAPORATOR UNIT MOUNTING BRACKET-POSITIONED AS MOUNTED IN DS CART

GROOVED RUBBER GROMMET WITH ¾ INCH HOLE ∅ ¾ INCH WASHERS- 4 ¼-20 LOCK NUTS – 4 ¼-20 SCREW – 1 SHORT ZIP TIES – 25 LONG ZIP TIES- 10 FLEXIBLE DRAINAGE TUBE-7 FT 3/8” RING TERMINALS-2 #8-32X ½ TRUSS HEAD SCREWS and ∅ ½ INCH WASHERS-4 EACH

--INSTALLATION--

NOTE - BEFORE BEGINNING INSTALLATION-

1. READ ALL INSTRUCTIONS AND WARNINGS 2. SET PARKING BRAKE 3. CHOCK CART WHEELS 4. DISCONNECT BATTERY 5. KEEP ALL HARDWARE THAT IS REMOVED FROM CART DURING INSTALLATION- IT

WILL BE REINSTALLED

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EVAPORATOR SECTION INSTALLATION 1. REMOVE EVAPORATOR FROM BOX. CAREFULLY UNCOIL TUBE BUNDLE AND PLACE

EVAPORATOR WITH BOLTS FACING UP ON A NON-ABRASIVE, STABLE SURFACE. 2. PLACE EVAPORATOR MOUNTING BRACKET ON EVAPORATIVE UNIT WITH THE SIDE FLANGES

OF THE BRACKET FACING UPWARDS AS SHOWN. LONG ½” FLANGE ON BRACKET SHOULD ALIGN WITH THE SIDE OF THE EVAPORATOR UNIT OPPOSITE THE NOZZLES AND KNOB OF UNIT AND WILL BE FACING DOWNWARDS TOWARDS UNIT.

3. SLIDE PROVIDED WASHERS OVER BOLTS. 4. INSTALL AND TIGHTEN ¼-20 LOCK-NUTS PROVIDED IN MOUNTING KIT 5. CUT BOLTS SUCH THAT BOLT END IS NEARLY FLUSH WITH NUT.

EVAPORATIVE UNIT WITH BRACKET INSTALLED SHOWING STUDS TO BE CUT JUST ABOVE THE MOUNTING NUT

CUT

6. REMOVE THE 4 LOCK NUTS FROM THE BOLTS AT FRONT END OF GOLF CART ROOF SUPPORT

(2 ON EACH SIDE OF SUPPORT). KEEP BOLTS, THEY WILL BE USED IN THE NEXT STEP.

REMOVE ROOF SUPPORT BOLTS AND LOCK NUTS 7. WITH NOZZLES AND KNOB FACING TOWARD THE PASSENGER COMPARTMENT, ALIGN THRU

HOLES OF BRACKET FLANGES WITH THE HOLES IN THE SUPPORT FROM WHICH THE BOLTS HAD BEEN REMOVED. INSERT BOLTS PREVIOUSLY REMOVED THRU THE BRACKET HOLES INTO THE ROOF SUPPORT HOLES FROM WHICH THEY HAD PREVIOUSLY BEEN REMOVED. TIGHTEN LOCK NUTS BACK ONTO BOLTS.

USE ACCESS HOLES IN BRACKET TO INSERT BOLTS

ACCESS HOLE

REINSTALLING ROOF SUPPORT BOLTS AND NUTS THROUGH EVAPORATOR MOUNTING BRACKET 71481 REV-REL (4/26/06)

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MOUNTED EVAPORATOR UNIT AS VIEWED FROM INSIDE OF CART INSTALL FLEX-LINE BUNDLE SUPPORT BRACKET 1. REMOVE BOLTS AND LOCK NUTS FROM REAR PASSENGER SIDE ROOF SUPPORT BRACKET. 2. HOLD FLEX-LINE BRACKET IN ONE HAND WHILE INSERTING BOLTS THROUGH BRACKET AND

ROOF SUPPORT AS SHOWN. TIGHTEN LOCK NUTS ONTO THROUGH BOLTS.

REINSTALLING REAR ROOF SUPPORT BRACKETS THROUGH SLOTS IN FLEX LINE MOUNTING BRACKET 3. INSERT ¼-20 SCREW PROVIDED WITH MOUNTING KIT THROUGH HOLE IN FLEX LINE BRACKET

INTO PEM NUT IN EVAPORATOR MOUNTING BRACKET, AS SHOWN. TIGHTEN.

¼-20 SCREW

INSTALLATION OF ¼-20 SCREW FROM KIT THROUGH HOLE IN FLEX LINE MOUNTING BRACKET INTO PEM NUT OF EVAPORATOR MOUNTING BRACKET. 71481 REV-REL (4/26/06)

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CONDENSING UNIT INSTALLATION 1. REMOVE SEAT FROM GOLF CART. REMOVE SCREWS HOLDING SEAT BACK ONTO CART

REMOVING SEAT REMOVING SCREWS FROM SEAT BACK

2. REMOVE BASKET SUPPORT BOLT, NUT AND WASHER FROM BAG SUPPORT BRACKET AT REAR OF CART. REMOVE BOLTS AND NUTS FROM ENDS OF SIDE SUPPORTS. REMOVE BAG SUPPORT BRACKET FROM REAR OF CART.

BAG SUPPORT BRACKET

BASKET SUPPORT BOLT, NUT WASHER

REAR BAG SUPPORT BOLT, NUT AND WASHER

BAG SUPPORT BRACKET INSTALLED BAG SUPPORT BRACKET REMOVED 3. REMOVE BASKET BOLTS, WASHERS AND NUTS FROM SIDE SUPPORTS. REMOVE BASKET.

SIDE SUPPORT

BOLT, NUT, WASHERS FROM SIDE SUPPORT

SIDE SUPPORT MOUNTING HARDWARE BASKET HAS BEEN REMOVED

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4. REMOVE SCREWS FROM REAR ACCESS PANEL BEHIND SEAT BACK. REMOVE PANEL.

REAR ACCESS PANEL

REMOVING SCREWS FROM REAR ACCESS PANEL REMOVING REAR ACCESS PANEL 5. REMOVE BOLTS FROM ROOF STRUTS BY REACHING INTO OPENING EXPOSED WHEN REAR ACCESS PANEL WAS REMOVED.

HOLD ROOF MOUNT BOLT HEAD WITH FINGER WHILE TURNING NUT 6. INSTALL RIGHT AND LEFT CONDENSER SUPPORT BRACKETS AS SHOWN, FIRST SLIDING

THE FRONT END OF THE BRACKET UNDER THE SEAT SUPPORTS THEN SLIDING THE BACK OF THE BRACKETS UNDER THE ROOF STRUTS.

SEAT BACK SUPPORT

ROOF SUPPORT BRACKET

LIFT SEAT BACK SUPPORT, SLIDE BRACKET UNDER LIFT ROOF STRUT, SLIDE BRACKET UNDER BRACKET

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7. REMOVE CONDENSING UNIT FROM BOX. LIFT RIGHT ROOF STRUT, SLIDE TUBING BUNDLE

UNDER ROOF STRUT. CAREFULLY REST CONDENSING UNIT ON FENDER COVER.

LIFT RIGHT ROOF STRUT, SLIDE BUNDLE UNDER STRUT REST CONDENSER UNIT ON RIGHT FENDER

8. REINSTALL ROOF STRUT BOLTS. TIGHTEN. REINSTALL PLASTIC REAR ACCESS PANEL AND

PANEL SCREWS; TIGHTEN SCREWS.

REINSTALL ROOF STRUT BOLTS REPLACE ACCESS PANEL

9. PLACE CONDENSING UNIT BETWEEN CONDENSING MOUNTING BRACKETS ALIGN HOLES IN CONDENSING UNIT WITH HOLES IN BRACKETS. INSTALL BLACK #8-32 PAN HEAD SCREWS WITH WASHERS THRU BRACKETS INTO HOLES IN CONDENSING UNIT. START ALL SCREWS LOOSELY TO ASSURE ALIGNMENT BEFORE TIGHTENING. TAKE CARE NOT TO CROSS THREAD SCREWS. DO NOT FORCE OR THREADS WILL STRIP.

8-32 SCREW WITH WASHER

LEFT BRACKET

PLACE CONDENSER UNIT BETWEEN BRACKETS, INSTALL BLACK WASHERS AND 8-32 SCREWS. DO NOT ALIGN HOLES IN BRACKET WITH HOLES IN UNIT. CROSS THREAD-DO NOT FORCE.

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10. REPLACE SEAT BACK SCREWS-THRU SEAT BACK BRACKET AND CONDENSER MOUNTING BRACKETS INTO CHASSIS OF CART.

REPLACE SEAT BACK SCREWS- TIGHTEN

FLEX-LINE AND CONDUIT BUNDLE INSTALLATION 1. CAREFULLY CUT ZIP TIES HOLDING POWER LEAD BUNDLE AGAINST MAIN FLEX LINE

BUNDLE. 2. STARTING AT THE EVAPORATOR SECURE FLEX-LINE BUNDLE WITH ZIP TIES PROVIDED IN

MOUNTING KIT. THE FIRST (SHORT) TIE WILL BE USED TO SECURE THE BUNDLE TO THE EVAPORATOR BRACKET ACCESS HOLE. SPACING THE ZIP TIES EVENLY ALONG THE LENGTH OF THE BRACKET, 7-9 INCHES APART, SECURE THE TUBE BUNDLE TO THE FLEX LINE SUPPORT BRACKET WITH SHORT ZIP TIES. ADDITIONALLY, SECURE THE BUNDLE TO THE FLEX LINE BRACKET THROUGH THE HOLE INDICATED IN THE BRACKET PHOTO.

3. CONTINUE SECURING THE TUBE BUNDLE, SPACING THE ZIP TIES EVENLY, DOWN THE REAR ROOF SUPPORT STRUTS. USE THE SHORT TIES. THE LONGER ZIP TIES SHOULD BE RESERVED FOR SECURING TO THE DOUBLED SQUARE TUBES AT THE REAR OF THE CART.

DO NOT SECURE POWER LEAD BUNDLE AT THIS TIME.

SHORT ZIP TIE

SHORT ZIP TIE

EVAPORATOR MOUNTING BRACKET

FLEX LINE MOUNTING BRACKET

SECURE BUNDLE THROUGH ACCESS HOLE IN SECURE BUNDLE THROUGH HOLE IN FLEX LINE EVAPORATOR MOUNTING BRACKET MOUNTING BRACKET AT REAR OF CART

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SHORT ZIP TIES

SECURE BUNDLE ALONG LENGTH OF FLEX LINE BRACKET THEN DOWN ROOF STRUT

LONG ZIP TIES

USE LONG ZIP TIES TO SECURE BUNDLE TO DOUBLE SQUARE TUBES AT REAR OF CART

4. PULL ZIP TIES TIGHT USING PLIERS. CUT OFF EXCESS LENGTH.

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WIRING

CAUTION!! BATTERIES- READ WARNINGS LISTED IN INSTRUCTIONS AND ON VEHICLE! BE SURE BATTERIES ARE CHARGED AND ARE IN GOOD REPAIR. DISCONNECT BATTERIES 1. CRIMP 3/8” RING TERMINALS TO ENDS OF RED AND BLACK LEADS. 2. ATTACH THE RED LEAD TO THE POSITIVE POST OF THE #1 BATTERY. ATTACH THE BLACK

LEAD TO THE NEGATIVE POST OF THE #4 BATTERY. NOTE THERE WILL BE A MINOR SPARK WHEN ATTACHING THE BLACK LEAD.

RED LINE BLACK LINE

SEAT BACK

SHORT ZIP TIES

WIRING

3. DOUBLE CHECK CONNECTION- REVERSED POLARITY WILL CAUSE CATASTROPHIC DAMAGE TO ELECTRONICS.

4. REATTACH BATTERIES TO CART. 5. SECURE EXCESS LEADS WITH ZIP TIE AS SHOWN. SECURE THE WIRING BUNDLE ENCLOSED IN

BLACK PLASTIC CONDUIT TO THE SEAT BACK SUPPORT LOCATED ON THE SAME SIDE OF THE CONDENSER UNIT AS THE TUBE BUNDLE. USE A SHORT ZIP TIE.

SHORT ZIP TIE

SEAT BACK SUPPORT

ATTACH WIRES IN CONDUIT TO SEAT BACK WITH ZIP TIE 6. TURN SWITCH ON EVAPORATIVE SECTION OF UNIT TO ‘ON’ FOR AIR-CONDITIONING ONLY

UNITS OR ‘COOL’ FOR HEAT PUMP UNITS. ONCE COOL AIR BEGINS TO FLOW THROUGH NOZZLES, TURN UNIT OFF.

7. REPLACE SEAT. 71481 REV-REL (4/26/06)

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INSTALLING FLEXIBLE DRAIN TUBE 1. PUSH AND TWIST DRAIN TUBE ONTO BARBED HOSE NIPPLE ON BOTTOM OF EVAPORATOR. 2. KEEPING TUBE AT ANGLE SUCH THAT FLOW THRU TUBE WILL BE AWAY FROM EVAPORATOR, SECURE DRAIN TUBE WITH ZIP TIE TO FROM ROOF SUPPORT OF DS CART, AS SHOWN.

NOTE DOWNWARD ANGLE OF DRAINAGE TUBE (CLEAR TUBE SHOWN) 3. SECURE TUBE ALONG THE REMAINING LENGTH OF ROOF SUPPORT. DO NOT SQUEEZE TUBE

SUCH THAT FLOW WILL BE RESTRICTED. END OF TUBE CAN EITHER REST AGAINST SIDE OF CART, ABOVE WHEEL, OR A 1” HOLE MAY BE DRILLED IN CART AND PROVIDED GROMMET INSERTED TO FINISH HOLE EDGES. DRAINAGE TUBE CAN THEN BE INSERTED INTO GROMMET. TUBE CAN BE CUT TO LENGTH AS NEEDED.

DRAINAGE TUBE (CLEAR SHOWN) SECURED ALONG LENGTH OF ROOF SUPPORT WITH SHORT ZIP TIES. HOLE MAY BE DRILLED IN CHASSIS AND GROMMET INSERTED

SHORT ZIP TIES

RECOMMENDED SITE OF HOLE FOR DRAIN TUBE INSERTION

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ALLOWING HOSE END TO TERMINATE AND DRAINAGE TO FLOW INTO THE WHEEL WELL. INSTALLING BASKET FROM KIT NOTE- YOU WILL NEED HARDWARE REMOVED PREVIOUSLY FROM BASKET MOUNTING IN ORDER TO INSTALL NEW BASKET. FOR PICTORIAL REPRESENTATION OF BASKET INSTALL SEE BASKET REMOVAL DESCRIPTION. 1. SLIDE BASKET FROM DS KIT UNDER BRACKET SUPPORTS. INSERT BOLTS THROUGH SIDE

SUPPORTS AND THROUGH BASKET SIDE BRACKETS ALIGNED WITH HOLES. INSTALL WASHERS AND NUTS REMOVED EARLIER. TIGHTEN NUTS.

2. REPLACE BAG SUPPORT BRACKET. REINSTALL SIDE SUPPORT ATTACHMENT BOLTS TO BAG SUPPORT BRACKET. REINSTALL WASHER, BOLT AND NUT THROUGH BAG SUPPORT BRACKET AND BASKET BRACKET. TIGHTEN ALL FASTENERS.

SIDE BRACKET BASKET SUPPORT NUTS, WASHERS AND BOLTS

BAG SUPPORT BRACKET NUTS, WASHERS AND BOLTS

BAG SUPPORT BRACKET-BASKET NUT, BOLT AND WASHER

BASKET INSTALLED POST INSTALLATION CARE AND MAINTENANCE 1. CHECK AND TIGHTEN ALL HARDWARE AFTER 40 HOURS OF OPERATION. 2. CHECK AND TIGHTEN ALL FASTENERS REGULARLY THROUGHOUT THE SERVICE LIFE OF THE

UNIT. 3. WHEN CLEANING CART DO NOT WET THE EVAPORATIVE UNIT- IT CONTAINS ELECTRONICS

THAT MUST NOT BE EXPOSED TO EXCESSIVE MOISTURE. THE EVAPORATIVE UNIT MAY BE CLEANED WITH A SOFT DAMP CLOTH BUT NO WATER SPRAY MAY BE USED.

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