Torque 600amp Controller 25-001

Add to my manuals
22 Pages

advertisement

Torque 600amp Controller 25-001 | Manualzz

Distributed Exclusively by Madjax

600A 48V or 36V DC MOTOR CONTROLLER

Installation/Service Manual

25-001/07

600amp controller

25-002

on-the-fly programmer

25-003

wiring harness for CLUB CAR

®

25-004

48v wiring harness for *E-Z-GO

®

TXT

®

25-005

36v wiring harness for *E-Z-GO

®

TXT

®

25-006

wiring harness for YAMAHA

®

Drive

®

installation instructions

Instructions for:

Club Car

®

Precedent

®

& DS

®

with Curtis 1510/1515 Controller

*E-Z-GO

®

TXT

®

48V with Curtis 1206HB Controller

*E-Z-GO

®

TXT

®

36V with Curtis 1206MX Controller

(

Requires 36V Firmware)

Yamaha

®

Drive

®

with Moric Controller JW2

INSTALLATION/SERVICE MANUAL

INTRODUCTION

600A 48V or 36V DC MOTOR CONTROLLER

The owner, and all vehicle operators MUST Read and Understand All Warnings and Instructions in this manual and in the Vehicle Owner/

Operator’s Manual. The owner of this vehicle assumes all liability for accidents, injuries or damages if the warnings and instructions are not followed.

Madjax assumes no responsibility for errors or omissions in this manual, in regards to liability or damages resulting from the use of information contained in the manual. If it is lost or damaged please contact your local dealer or Madjax.

Madjax reserves the right to make changes to the controller, parts of the controller, accessories, labeling or instructions without obligation to make these changes on units previously sold.

Product and specifications are subject to change without notice or obligation.

ATTENTION:

BEFORE INSTALLING THIS CONTROLLER PLEASE RECORD THE SERIAL NUMBER LOCATED ON THE

BODY OF THE CONTROLLER.

PART

TORQUE 600AMP 48V DC CONTROLLER

TORQUE 600AMP 36V DC CONTROLLER

SERIAL #

*DISCLAIMER

*E-Z-Go

®

, E-Z-Go

®

TXT

®

, and E-Z-Go

®

RXV

®

are registered trademarks of Textron Innovations, Inc. Club Car

®

, Club Car

®

Precedent

®

, and Club Car

®

DS

®

are registered trademarks of Ingersoll Rand, Inc. Yamaha

®

, Yamaha

®

Drive

®

, G-14

®

, G-16

®

,

G-19

®

, and G-22

®

are registered trademarks of Yamaha Golf-Car Company. Any reference to Club Car

®

, E-Z-Go

®

, or

Yamaha

®

or their associated trademarks, word marks, and products are only for purposes of identifying golf carts with which this Madjax

®

product is compatible. Madjax

®

products are aftermarket parts and are not original equipment parts. Madjax

®

is not connected to, affiliated with, sponsored by, or endorsed by either Textron Innovations, Inc., Ingersoll Rand, Inc., Yamaha

Golf Cart Company, or any of their parent or subsidiary companies.

2

INSTALLATION/SERVICE MANUAL

WARNINGS

SAFETY WARNINGS

MAKE SURE TO READ and UNDERSTAND the OWNER’S INSTALLATION and SERVICE MANUAL and ALL WARNING LABELS with this Controller.

Make sure to also Read, Understand and follow the Vehicle’s OWNER’S MANUAL and ALL INSTRUCTIONS and WARNING

LABELS.

FAILURE to follow ALL WARNINGS AND INSTRUCTIONS can damage the Controller and /or the Vehicle and/or cause SERIOUS

INJURY OR DEATH!

• Do not leave children or pets unattended in or near the vehicle.

• Never drive too fast! The Terrain, conditions and the operator’s skill will determine a safe speed.

• Drive at a reduced speed and use extra caution when carrying passengers or cargo.

• Avoid sharp turns and do not accelerate quickly when turning.

• Always look behind you before and while backing up.

• Reduce speed when towing and allow more room for stopping and turning.

MOTOR KIT OPERATION

• Slow down and use brakes when going down hills.

2. Move the SilverWolf Power Switch from OFF to RUN or HIGH depending on how much power is required.

Note: The Motor System can be turned On or Off at anytime of operation.

proceed with caution or choose a safer route.

3. ALWAYS look around the vehicle to make sure the area is clear before operating the vehicle!

• When towing this vehicle make sure the key is turned off, the Run/Tow switch is in Tow, and batteries main power is disconnected.

• Never re-wire, by-pass or change the wires, switches, or controller. Contact your dealer or the manufacturer if vehicle is not operating correctly.

DANGER

FAILURE to follow the WARNINGS below can damage the Vehicle and/or cause SERIOUS INJURY OR DEATH!

LABELS with this Motor Kit.

our web site at www.silverwolfmotors.com. Or call 1-866-410-5297 conditions and the operator’s skill will determine a safe speed. Avoid sharp turns and do not accelerate quickly when turning; this can cause the vehicle to slide sideways or skid out of control. Abrupt maneuvers or aggressive driving can cause a rollover even on flat open areas.

• This Motor Kit will increase torque and traction; but this Does Not increase the GVWR (Gross Vehicle Weight

DANGER

FAILURE to follow the WARNINGS below can damage the Vehicle and/or cause SERIOUS INJURY OR DEATH!

©2014 SilverWolf Vehicles Inc. Patents Pending.

Part # PM00501

MAKE SURE TO READ and UNDERSTAND the OWNER’S INSTALLATION and SERVICE MANUAL and

ALL WARNING LABELS with this Controller.

• Always proceed with caution. Keep speed low and do not drive faster than conditions permit. The terrain, conditions and the operator’s skill will determine a safe speed. Avoid sharp turns and do not accelerate quickly when turning; this can cause the vehicle to slide sideways or skid out of control. Abrupt maneuvers or aggressive driving can cause a rollover even on flat open areas.

• This Controller will increase torque, but Does Not increase the GVWR (Gross Vehicle Weight Rating), Cargo capacity or Towing capacity of the Vehicle. Always follow the Vehicle towing and loading specifications.

3

INSTALLATION/SERVICE MANUAL

CONTROLLER PARTS LIST

Confirm that all parts listed below are with your kit before starting installation.

This kit includes either the 600 AMP 48V Controller or the 36V Controller.

If you are missing parts please contact your local dealer or SilverWolf Vehicles Inc.

PART DESCRIPTION

1* TORQUE 600 AMP 48V Controller

1* TORQUE 600 AMP 36V Controller

2 M8 X 16 Hex Cap 8.8 Zinc (Not Shown)

3 M6 X 16 Hex Cap 8.8 Zinc (Not Shown)

4 M8 Lock Washer (Not Shown)

5 M6 Lock Washer (Not Shown)

6 M8 Flat Washer (Not Shown)

7 M6 Flat Washer (Not Shown)

8 Spade Connector 6.3MM (for Club Car Precedent & DS, *E-Z-GO TXT 36V

Yamaha Drive)

9 2 AWG 5/16” Ring Terminal (Yamaha Drive Only!)

1

PART #

CDC648

CDC636

80-000901

80-000902

80-000910

80-000909

80-000888

80-000889

20-001010

EW2G516

QTY

1

3

2

2

2

3

1

3

2

1

8 9

WIRING PARTS LIST

This kit includes only one of the Vehicle Module Harnesses listed below. Note: some Modules look similar. Make sure to check the part number and description label on the bottom of the Module before connecting to the Controller.

PART DESCRIPTION PART # QTY

1* MJ Vehicle Module Harness for Curtis 1510/1515 Controller (Club Car Precedent / DS) W600100 1*

1* MJ Vehicle Module Harness for Curtis 1206MX Controller (*E-Z-GO® *TXT® 36V)

1* MJ Vehicle Module Harness for Curtis 1206HB Controller (*E-Z-GO® *TXT® 48V)

1* MJ Vehicle Module Harness for Moric JW2 Controller(Yamaha Drive)

W600200

W600201

W600300

1*

1*

1*

1* MJ Vehicle Module Harness for Curtis 1264, 1268ITS W600400 1*

1

*

NOTE: Club Car Precedent Vehicle Module Harness Shown

4

INSTALLATION/SERVICE MANUAL

INSTALLATION INSTRUCTIONS

ATTENTION:

Before installing the Controller make sure that the Golf Car’s Electrical

System is working properly.

All components such as the Motor, Run/Tow Switch, Pedal Cluster,

FWD/REV Switch and all Wiring needs to be in good condition and operating to Manufacturers Standards.

If the system is not working properly this must be repaired before installing this Controller!

DANGER

FAILURE to follow the WARNINGS below can damage the Vehicle and/or cause SERIOUS INJURY OR DEATH!

Installation or Servicing of the 600 AMP Controller Must be done by a trained golf car technician.

Before installing or servicing of the 600 AMP Controller;

• Make sure the Run/Tow Switch is in the Tow position

• The Key is turned OFF and Removed from the Ignition

• The Parking Brake is Engaged

• Disconnect the Main (+) Positive and (-) Negative Cable on the Vehicle’s Battery System.

• Before testing the Controller/ Vehicle make sure ALL four wheels are off the ground and supported with jack stands.

• The area around the vehicle must be clear. Keep all People, Children and Pets away from the vehicle when installing, servicing or testing the vehicle.

• Read 600 AMP Controller Installation /Service Manual and All Warning Labels before servicing or troubleshooting this Vehicle.

• The Controller is sealed and can not be opened for service. To replace the Controller call your local dealer. Opening the Controller will Void the Warranty

• Wear Safety Glasses and Gloves when installing this Controller.

• Wear a Safety Shield when working in or near the Vehicle Battery Compartment.

• Use Insulated Tools to protect from electric shock.

• Never lay or put down tools in the Vehicle Battery Compartment.

Tools Required

• Ratchet Set

• Open End Wrench Set

• Electrical Tape

• Small Saw or Dremmel tool (Club Car Precedent)

• 4 Jack Stands

• Lift Jack (2 ton or more)

• Wheel Chocks

• Multimeter

5

INSTALLATION/SERVICE MANUAL

INSTALLATION INSTRUCTIONS

Wire & Connector Location Diagram

600 AMP Vehicle Module Harness

NOTE: Module shown is for the Club

Car Precedent, DS and the *E-Z-GO®

TXT® 48V, for Connector location for other Vehicles see the installation instructions for the specific Vehicle.

Connector Plug Location

1 Vehicle 16 Pin

2 OTF

3 4WD

8 Pin

3 Pin

Vehicle Harness

Connector

“On The Fly” Programmer

*(Optional) Not included

SilverWolf 4WD System

(WH03500 Extension

Cable)

2

3

1

600 AMP Wire Location

F2

BM

STATUS

LIGHT

B+

F1

F1

B-

FIELD WIRE

MAIN BATTERY

NEGATIVE

Field Switch Wire

BLACK Negative Cable from

Battery.

Also Connect SilverWolf

BLACK Negative Battery

Cables if installed.

M MOTOR

B+

MAIN BATTERY

POSITIVE

RED Positive Cable from

Battery.

Also Connect SilverWolf RED

Positive Battery Cables if installed.

Field Switch Wire

F2 FIELD WIRE

NOTE: F1 & F2 Field Wires if installed incorrectly the

FWD/REV Switch will work in opposite direction.

The 600 AMP Controller has a Green and Red Status Light that will indicate the status of the Controller. It is located inside the controller and is visible through the top cover when the controller is powered.

6

MOTOR KIT OPERATION

1. Insert and turn vehicle key to Run.

INSTALLATION/SERVICE MANUAL

2. Move the SilverWolf Power Switch from OFF to RUN or HIGH depending on how much power is required.

INSTALLATION INSTRUCTIONS

3. ALWAYS look around the vehicle to make sure the area is clear before operating the vehicle!

Club Car Precedent with Curtis 1510/1515 Installation

DANGER

FAILURE to follow the WARNINGS below can damage the Vehicle and/or cause SERIOUS INJURY OR DEATH!

Before removing the original Controller take note or take a photo of the 5 Controller Posts and their corresponding Wires. Make sure that all groups of wires stay together.

Remove (A) the Vehicle Controller Cover and the Original Vehicle Controller. (B) Install the 600 AMP Controller using the 3 screws from the original controller. driving can cause a rollover even on fl at open areas.

A

This Motor Kit will increase torque and traction; but this Does Not increase the GVWR (Gross Vehicle Weight specifi cations.

B

Rating), Cargo capacity or Towing capacity of the Vehicle. Always follow the Vehicle towing and loading

*This Label must be placed on the Vehicle in an area that is in view of the Driver and Passenger(s).

©2014 SilverWolf Vehicles Inc. Patents Pending.

Part # PM00501

SEE PHOTOS ON FOLLOWING PAGE

(C) Connect the Motor Cable from the original Controller to the M Post on the 600A Controller using a M8 Bolt, Lock Washer and Flat Washer.

(D) Connect the Main Positive Red Power Cable along with the 2 SilverWolf 4WD Positive Red Power Cables (if installed) to the B+ Post on the Controller using a M8 Bolt, Lock Washer and Flat Washer.

(E) Connect the Main Negative Black Power Cable along with the 2 SilverWolf 4WD Negative Black Power Cables (if installed) to the B- Post on the Controller using a M8 Bolt, Lock Washer and Flat Washer.

(F) Install the F1 Field Wire from the original Controller to the F1 Post on the Controller using a Spade Connector and a M6

Bolt, Lock Washer and Flat Washer. (G) Install the F2 Field Wire from the original Controller to the F2 Post on the Controller

Post using a Spade Connector and a M6 Bolt, Lock Washer and Flat Washer.

NOTE: Use these Spade Connectors on the F2 and F1 posts.

7

INSTALLATION/SERVICE MANUAL

INSTALLATION INSTRUCTIONS

Club Car Precedent with Curtis 1510/1515 Installation cont’d.

G

E

C

D

F

G

E

C

D

F

(H) Install the 25-003 20 Pin Connector on the Vehicle Module Harness to the Controller. Note: The plastic around this plug will need to be cut away to allow for the Body Cover to be re-installed. See the Cut Out instructions below.

(I) Install the 16 Pin Connector from the Vehicle Wiring Harness to the 16 Pin Connector on the Vehicle Module Harness.

(J) If the Vehicle has a SilverWolf 4WD System connect the Extension Harness from the Main Harness into the 3 Pin Connector on Vehicle

Module Harness.(K) This 8 Pin Connector is for the optional OTF “On The Fly” Programmer.

Cut Out Instructions

H

2”

5.5”

2.5”

J

K

.5”

If the Precedent has a six 8V Battery layout, the plastic on

Controller/Wiring Cover will need to be cut out to allow the 20 pin

Connector on the Vehicle Module Harness to fit properly.

Caution: Remove the Vehicle Module Harness before cutting in to the plastic Cover.

Measure in from the outer right side of the cover 5.5” inches. Use a

2” wide piece of tape to cover and area 2” wide x 2.5” high.

I

Now the Vehicle’s Main Battery Positive and Negative Cables can be re-connected.

8

4. Move the SilverWolf Power Switch to the OFF position when the vehicle is not in use.

DANGER

FAILURE to follow the WARNINGS below can damage the Vehicle and/or cause SERIOUS INJURY OR DEATH!

Before removing the original Controller take note or take a photo of the 5 Controller Posts and their corresponding Wires. Make sure that the groups of wires stay together.

Remove (A) the Vehicle Controller Cover and the Original Vehicle Controller. (B) Install the 600 AMP Controller using the 3 screws from the original controller.

(C) Connect the Motor Cable from the original Controller to the M Post on the 600A Controller using a M8 Bolt, Lock Washer and Flat Washer.

(D) Connect the Main Positive Red Power Cable along with the 2 SilverWolf 4WD Positive Red Power Cables (if installed) to the B+ Post on the Controller using a M8 Bolt, Lock Washer and Flat Washer.

*This Label must be placed on the Vehicle in an area that is in view of the Driver and Passenger(s).

(E) Connect the Main Negative Black Power Cable along with the 2 SilverWolf 4WD Negative Black Power Cables (if installed) to the B- Post on the Controller using a M8 Bolt, Lock Washer and Flat Washer.

Part # PM00501

(F) Install the F1 Field Wire from the original Controller to the F1 Post on the Controller using a Spade Connector and a M6

Bolt, Lock Washer and Flat Washer. (G) Install the F2 Field Wire from the original Controller to the F2 Post on the Controller

Post using a Spade Connector and a M6 Bolt, Lock Washer and Flat Washer.

A

B

G

E

C D

F

9

INSTALLATION/SERVICE MANUAL

25-004 INSTALLATION INSTRUCTIONS

*E-Z-GO

®

TXT

®

48V with Curtis 1206HB Installation cont’d.

(G) Install 25-004 on the Vehicle Module Harness to the Controller.

(H) Install the 16 Pin Connector from the Vehicle Wiring Harness to the 16 Pin Connector on the Vehicle Module Harness.

(I) If the Vehicle has a SilverWolf 4WD System connect the Extension Harness from the Main Harness into the 3 Pin Connector on Vehicle

Module Harness.

NOTE: The Module should be oriented and secured with Zip Ties so that water and debris does not accumulate in the Connectors.

G

H

I

Now the Vehicle’s Main Battery Positive and Negative Cables can be re-connected.

10

MOTOR KIT OPERATION

1. Insert and turn vehicle key to Run.

INSTALLATION/SERVICE MANUAL

INSTALLATION INSTRUCTIONS

3. ALWAYS look around the vehicle to make sure the area is clear before operating the vehicle!

*E-Z-GO® *TXT® 36V with Curtis 1206MX Installation

DANGER

FAILURE to follow the WARNINGS below can damage the Vehicle and/or cause SERIOUS INJURY OR DEATH!

Before removing the original Controller take note or take a photo of the 5 Controller Posts and their corresponding Wires. Make sure that the groups of wires stay together.

Remove (A) the Vehicle Controller Cover and the Original Vehicle Controller. Remove the Solenoid Bracket from the Solenoid and the

Controller Mounting Plate. Note: The Solenoid Bracket will not be re-installed.

(B) Install the 600 AMP 36V Controller using the 3 screws from the original controller. Note: These Screws will be going into non-threaded holes but the Screws are self tapping Screws and will make their own threads.

(C) Attach the Solenoid using the 2 Screws from the Solenoid Bracket to the area below the Controller. Note: There are 2 holes already drilled.

*This Label must be placed on the Vehicle in an area that is in view of the Driver and Passenger(s).

A

C

Part # PM00501

B

Connector Plug Location Vehicle Module Harness *E-Z-GO TXT 36V

1 Vehicle 3 Pin

Vehicle Harness Connector

2 Vehicle 4 Pin

Vehicle Harness Connector

3 Vehicle 4 Pin

Vehicle Harness Connector

4 Vehicle 10 Pin

Vehicle Harness Connector

1

2

5

5 4WD 3 Pin

6 OTF 8 Pin

SilverWolf 4WD System

(WH03500 Extension Cable)

“On The Fly” Programmer

*(Optional) Not included

3

4

6

11

INSTALLATION/SERVICE MANUAL

INSTALLATION INSTRUCTIONS

*E-Z-GO® *TXT® 36V with Curtis 1206MX Installation cont’d.

(D) Connect the Motor Cable from the original Controller to the M Post on the 600A Controller using a M8 Bolt, Lock Washer and Flat Washer.

(E) Connect the Main Positive Red Power Cable from the Vehicle Solenoid along with the 2 SilverWolf 4WD Positive Red Power Cables (if installed) to the B+ Post on the Controller using a M8 Bolt, Lock Washer and Flat Washer.

(F) Connect the Main Negative Black Power Cable along with the 2 SilverWolf 4WD Negative Black Power Cables (if installed) to the B- Post on the Controller using a M8 Bolt, Lock Washer and Flat Washer.

(G) Install the F1 Field Wire (usually green) from the original Controller to the F1 Post on the Controller using a Spade

Connector and a M6 Bolt, Lock Washer and Flat Washer.

(H) Install the F2 Field Wire (usually black) from the original Controller to the F2 Post on the Controller Post using a Spade

Connector and a M6 Bolt, Lock Washer and Flat Washer.

I

H F

D E

G

J

2

1

4

3

NOTE: Use these

Spade Connectors on the F2 and F1 posts.

See the “CONNECTOR PLUG LOCATION” Chart on the previous page and photo I above to connect the Vehicle Connectors to the Vehicle

Module Harness.

(I) Install the 25-005 20 Pin Connector on the Vehicle Module Harness to the Controller.

(J) Install the Connectors from the Vehicle Wiring Harness to the Connectors on the Vehicle Module Harness as shown in the “CONNECTOR

PLUG LOCATION” Chart on the previous page. Note: If the Vehicle has a SilverWolf 4WD System connect the Extension Harness from the

Main Harness into the 3 Pin Connector on Vehicle Module Harness (Shown as # 5 on the previous page).

NOTE: The Module should be oriented and secured with Zip Ties so that water and debris does not accumulate in the Connectors.

(K) If re-installing the Controller Cover with the RUN/TOW Switch the Cover, will need to be cut off at the bottom because of the new

Solenoid location. Use a Saw to cut the bottom 2”’s of the Cover. Plug in the 4 pin Connector from the RUN/TOW Switch to the SW Vehicle

Module Harness and reinstall the Controller Cover.

NOTE: The Module should be oriented and secured with Zip Ties so that water and debris does not accumulate in the Connectors.

Now the Vehicle’s Main Battery Positive and Negative Cables can be re-connected.

12

INSTALLATION INSTRUCTIONS

Note: The Motor System can be turned On or Off at anytime of operation.

Yamaha Drive with Moric JW2 Installation

4. Move the SilverWolf Power Switch to the OFF position when the vehicle is not in use.

DANGER

FAILURE to follow the WARNINGS below can damage the Vehicle and/or cause SERIOUS INJURY OR DEATH!

LABELS with this Motor Kit.

CAUTION: DO NOT CONNECT ANY WIRES OR CABLES UNTIL AFTER STEP C.

A when turning; this can cause the vehicle to slide sideways or skid out of control. Abrupt maneuvers or aggressive driving can cause a rollover even on fl at open areas.

This Motor Kit will increase torque and traction; but this Does Not increase the GVWR (Gross Vehicle Weight

Rating), Cargo capacity or Towing capacity of the Vehicle. Always follow the Vehicle towing and loading specifi cations.

B

*This Label must be placed on the Vehicle in an area that is in view of the Driver and Passenger(s).

©2014 SilverWolf Vehicles Inc. Patents Pending.

Part # PM00501

Locate (C) the Y cable on the Vehicle Harness: shown as A2 in the photo below. This cable consists of 2 cables crimped together in to a Ring Terminal. The one side comes from the Battery Negative and the other side comes from the A2 on the Motor. Use a pair of side cutters to cut the A2 side of the cable at the Ring Terminal. Then crimp on a new ring terminal (included in the Vehicle Module Harness bag). NOTE: The Ring Terminals on the original Vehicle Harness may need to be drilled out to 5/16” to allow the Vehicle Harness to be connected to the new Controller.

C

1 2

3

CUT

B+

A2

A2

A2

B-

SEE PHOTO ON FOLLOWING PAGE

(D) Connect the Motor Cable (usually white) from the original Controller to the M Post on the 600A Controller using a M8

Bolt, Lock Washer and Flat Washer.

(E) Connect the Main Positive Red Power Cable from the Vehicle Solenoid and the Black A2 Cable (Cable that was cut and has the New Ring

Terminal) along with the 2 SilverWolf 4WD Positive Red Power Cables (if installed) to the B+ Post on the Controller using a M8 Bolt, Lock

Washer and Flat Washer.

(F) Connect the Main Negative Black Power Cable (Cable from the Battery with the original Ring Terminal) along with the 2 SilverWolf 4WD

Negative Black Power Cables (if installed) to the B- Post on the Controller using a M8 Bolt, Lock Washer and Flat Washer.

(G) Install the F1 Field Wire (usually green) from the original Controller to the F1 Post on the Controller using a Spade

Connector and a M6 Bolt, Lock Washer and Flat Washer.

(H) Install the F2 Field Wire (usually black) from the original Controller to the F2 Post on the Controller Post using a Spade

Connector and a M6 Bolt, Lock Washer and Flat Washer.

13

INSTALLATION/SERVICE MANUAL

INSTALLATION INSTRUCTIONS

Yamaha Drive with Moric JW2 Installation cont’d.

NOTE: Use these

Spade Connectors on the F2 and F1 posts.

D

F

H

G

E

A2

E

D

G

H

F

E

(I) Install the 25-006 20 Pin Connector on the Vehicle Module Harness to the Controller.

(J) Install the 26 PIN Connector from the Vehicle Wiring Harness to the 26 Pin Connector on the Vehicle Module Harness.

(K) If the Vehicle has a SilverWolf 4WD System connect the Extension Harness from the Main Harness into the 3 Pin Connector on Vehicle

Module Harness. (L) This 8 Pin Connector is for the optional OTF “On The Fly” Programmer.

I

J

K

L

NOTE: The Module should be oriented and secured with Zip

Ties so that water and debris does not accumulate in the

Connectors.

Connector Plug Location

2 4WD

3 OTF

4 Vehicle

25-006 Vehicle Module Harness (Yamaha DR.)

4

2

3 Pin

SilverWolf 4WD System

(WH03500 Extension Cable)

8 Pin

“On The Fly” Programmer

*(Optional) Not included

26 Pin Vehicle Harness Connector

3

1

Now the Vehicle’s Main Battery Positive and Negative Cables can be re-connected.

14

INSTALLATION/SERVICE MANUAL

25-002 INSTALLATION INSTRUCTIONS

OTF “On the Fly” Programmer (Optional)

DANGER

FAILURE to follow the WARNINGS below can damage the Vehicle and/or cause SERIOUS INJURY OR DEATH!

Vehicle Module Harness

OTF 8 Pin Connector

PART #

25-002

Speed: Top speed / Low speed

Regeneration: Motor Braking (How the brakes react to the

depression of the accelerator)

Accel: Torque behind take off speed

To install The OTF “On the Fly” Programmer

• First make sure the Vehicle RUN/TOW Switch is in the TOW position and the Key is turned off.

• The OTF can be mounted on the Vehicle or removed and used as required for programming purposes.

• The OTF has a long enough Cable to allow it to be mounted to the Dash area. Make sure to run the Cable in an area where it can not

MOTOR KIT OPERATION the Dash.

3. ALWAYS look around the vehicle to make sure the area is clear before operating the vehicle!

4. Move the SilverWolf Power Switch to the OFF position when the vehicle is not in use.

DANGER

FAILURE to follow the WARNINGS below can damage the Vehicle and/or cause SERIOUS INJURY OR DEATH!

MAKE SURE TO READ and UNDERSTAND the OWNER’S INSTALLATION and SERVICE MANUAL and ALL WARNING

LABELS with this Motor Kit.

To program the desired settings into the controller:

• Turn the lock out key from the Lock to Unlock.

Rating), Cargo capacity or Towing capacity of the Vehicle. Always follow the Vehicle towing and loading specifi cations.

• Turn the key to Lock in the setting and remove the key from programmer.

MOTOR KIT OPERATION

NOTE: The Key allows the operater to lock the settings on the Controller. Once the OTF is locked or unplugged from the Controller the settings can not be changed.

3. ALWAYS look around the vehicle to make sure the area is clear before operating the vehicle!

4. Move the SilverWolf Power Switch to the OFF position when the vehicle is not in use.

DANGER

FAILURE to follow the WARNINGS below can damage the Vehicle and/or cause SERIOUS INJURY OR DEATH!

MAKE SURE TO READ and UNDERSTAND the OWNER’S INSTALLATION and SERVICE MANUAL and ALL WARNING

LABELS with this Motor Kit.

• Always proceed with caution. Keep speed low and do not drive faster than conditions permit. The terrain, conditions and the operator’s skill will determine a safe speed. Avoid sharp turns and do not accelerate quickly when turning; this can cause the vehicle to slide sideways or skid out of control. Abrupt maneuvers or aggressive driving can cause a rollover even on fl at open areas.

Rating), Cargo capacity or Towing capacity of the Vehicle. Always follow the Vehicle towing and loading specifi cations.

*This Label must be placed on the Vehicle in an area that is in view of the Driver and Passenger(s).

©2014 SilverWolf Vehicles Inc. Patents Pending.

Part # PM00501

INSTALLATION/SERVICE MANUAL

INSTALLATION INSTRUCTIONS

MOTOR KIT OPERATION

1. Insert and turn vehicle key to Run.

2. Move the SilverWolf Power Switch from OFF to RUN or HIGH depending on how much power is required.

Note: The Motor System can be turned On or Off at anytime of operation.

3. ALWAYS look around the vehicle to make sure the area is clear before operating the vehicle!

4. Move the SilverWolf Power Switch to the OFF position when the vehicle is not in use.

Controller Pre-Drive Test:

1. Move the Run/Tow Switch to the Run position.

2. Insert and turn Key to ON

3. Move Vehicle’s FNR switch to the Forward position.

*This Label must be placed on the Vehicle in an area that is in view of the Driver and Passenger(s).

DANGER

FAILURE to follow the WARNINGS below can damage the Vehicle and/or cause SERIOUS INJURY OR DEATH!

4. Step on the Accelerator to test that the Vehicle is operating. Repeat this test with the switch in the

Reverse position.

driving can cause a rollover even on fl at open areas.

• This Motor Kit will increase torque and traction; but this Does Not increase the GVWR (Gross Vehicle Weight

Rating), Cargo capacity or Towing capacity of the Vehicle. Always follow the Vehicle towing and loading specifi cations.

*This Label must be placed on the Vehicle in an area that is in view of the Driver and Passenger(s).

If the Rear Wheels of the vehicle are not running properly during the Pre-Drive Test see the chart below to test the Vehicle Switches.

NOTE: On the OTF the LED will flash once when the Key, Forward, Reverse, or Foot Switch is activated and at 100%.

The following test procedures are to show that the Controller is getting the correct signals.

If a OTF Programmer was not purchased the Vehicles Reverse Buzzer will beep (if it is connected) and this can be used for the test procedures.

CONTROLLER INPUT SIGNAL CHECK

TEST

1

Key Switch

2

Forward

3

Reverse

ACTION

Turn Key Switch to ON

Move Switch to Forward

Move Switch to Reverse

RESULT

1 Green Flash/ Beep

1 Green Flash/ Beep

1 Green Flash/ Beep

YES NO

OK

OK

OK

Replace Key Switch

Replace FNR Switch

Replace FNR Switch

4

Foot Switch Slowly depress the Accelerator 1 Green Flash/ Beep OK Replace Throttle Sensor/ or Throttle

5

100% Throttle Continue to depress Accelerator to Floor.

1 Green Flash/ Beep OK Replace Throttle Sensor/ or Throttle

MOTOR KIT OPERATION

1. Insert and turn vehicle key to Run.

2. Move the SilverWolf Power Switch from OFF to RUN or HIGH depending on how much power is required.

Note: The Motor System can be turned On or Off at anytime of operation.

Controller Drive Test:

3. ALWAYS look around the vehicle to make sure the area is clear before operating the vehicle!

4. Move the SilverWolf Power Switch to the OFF position when the vehicle is not in use.

DANGER

FAILURE to follow the WARNINGS below can damage the Vehicle and/or cause SERIOUS INJURY OR DEATH!

MAKE SURE TO READ and UNDERSTAND the OWNER’S INSTALLATION and SERVICE MANUAL and ALL WARNING

This test will show that the Controller is installed and running correctly. conditions and the operator’s skill will determine a safe speed. Avoid sharp turns and do not accelerate quickly when turning; this can cause the vehicle to slide sideways or skid out of control. Abrupt maneuvers or aggressive driving can cause a rollover even on fl at open areas.

BEFORE YOU RUN THE FINAL TEST COMPLETE THE FOLLOWING STEPS: specifi cations.

*This Label must be placed on the Vehicle in an area that is in view of the Driver and Passenger(s).

1. Lift the Vehicle to allow the Jack Stands to be removed and the Vehicle to be lowered back to the ground.

2. Make sure the area around the Vehicle is clear; No people, children, pets, or objects that could come in contact with the Vehicle.

3. Move the Run/Tow Switch to Run

4. Turn the Key to Run and dis-engage the Parking Brake

5. Drive the Vehicle to an open area. Slowly Accelerate allowing time to get use to the extra power.

16

INSTALLATION/SERVICE MANUAL

TROUBLESHOOTING

DANGER

Failure to follow the Warnings in this Manual can damage the Vehicle and/or cause SERIOUS INJURY OR

DEATH.

Service of the 600A Controller Must be done by a trained golf car technician.

Before troubleshooting the 600 AMP Controller;

• Make sure the Run/Tow Switch is in the Tow position

• The Key is turned OFF

• The Controller is sealed and can not be opened for service. Opening the Controller will Void the

Warranty

PRELIMINARY TROUBLESHOOTING

Vehicle Module Harness Connector

Tools Required:

Digital Multimeter

PIN 10

This Connector is part of the Vehicle Module Harness that is attached to the Controller.

ISSUE

Vehicle/ Controller does not power up.

POSSIBLE CAUSES

• RUN/TOW off.

• Discharged/ Bad Batteries

• Wiring and Connectors

• Correct voltage at Controller

HOW TO CHECK

• RUN/TOW Switch in RUN position.

• Check Battery Pack voltage (It needs to be at least 31V to power up)

• Check All Wires for damage or loose connections.

• Check that the pins are fully seated in the Connectors (by tugging lightly on the individual wires) and that the Connectors are fully seated and locked into place.

• Check the voltage at the Controller between B+ and B- (it should be the pack voltage).

• Check the voltage between Pin 10 of the Vehicle Module Harness’s

20 Pin Connector and the B-. (it should be pack voltage).

• Replace SW Vehicle Module Harness • Faulty SW Vehicle Module

Harness

If there is pack voltage at the Controller between B+, Pin 10 and B- replace the Controller and re-test.

FLASH CODE TROUBLESHOOTING

The MADJAX 600A Controller has both a Red and a Green LED Status Light that will indicate the status of the Controller. It is located inside the Controller and is visible through the Top Cover when the Controller is powered. The vehicle’s reverse buzzer will also chirp the flash code in the event of a fault.

Note: If the Optional “On the Fly” Programmer was purchased it is also equipped with a BLUE LED Status Light. This light will indicate the same Flash Codes except they will be in Green only.

GREEN LED Status Light will repeatedly flash twice if the Key Switch is OFF indicating the Controller is in Standby Mode.

GREEN LED Status Light will be on solid if the Key Switch is ON

The vehicle is ready to operate if the Red LED Status Light is not flashing.

RED LED Status Ligh t flashing see the Flash Code Chart Below

RED LED Status Light contains a 2 digit code;

The 1st digit will appear and then there will be a 1 second pause before the 2nd digit appears. There will be a 2 second pause before the error code repeats itself.

ie. 1 flash followed by a 1 second pause then 2 flash indicates 1-2 the performance is limited because the Motor or Controller is Hot.

17

1 - 1 Voltage

Issue:

Batteries

INSTALLATION/SERVICE MANUAL

TSX V2 TROUBLESHOOTING

FLASH

CODES

FLASH CODE

MESSAGE

1 - 1 Voltage

Issue:

Batteries

DESCRIPTION

Batteries are empty or too low.

Batteries too full

SOLUTION

• Recharge Batteries

• Check for bad or damaged

Batteries.

• Check Battery Cables are not loose or damaged.

• Check Solenoid

• Batteries can not take a charge. Check the Batteries, one or more Batteries may be bad.

HOW TO CHECK

• Use a Battery Load Tester to verify Battery condition after charging.

• Connect Volt Meter to Main and on the Batteries. (Use alligator clips).

Measure the voltage while driving to see if the voltage drops.

• Attach Volt Meter to and on the

Controller if the voltage drops at the

Controller and not at the Battery then the

Solenoid may be bad.

• Use a Battery Load Tester to verify Battery condition after charging.

1 - 1 Voltage

Issue:

Solenoid

(Contactor)

Damaged Solenoid or loose Wiring

• Confirm the Solenoid is w orking properly. Change

Solenoid if required.

1 - 2 Temperature

(Controller)

1 - 3 Charger

Interlock

Performance is limited because the Controller is Hot.

• Let Vehicle cool off; system is over worked.

Charger is connected. • Disconnect the Charger before trying to move.

Vehicle Charging Port may be wet

• Dry and clean the Charger

Port

On Board Computer

(OBC) is in sleep mode.

• Depress the throttle twice to wake up OBC.

• Replace Charger port on

Vehicle

1 - 4 Temperature

(Motor)

Performance is limited because the Motor is

Hot.

2 - 1 Switch Fault Both FWD & REV signal came on at the same time.

• Let Vehicle cool off; system is over worked.

• Check and replace FWD &

REV Switch

• Put Vehicle in neutral and listen for the Solenoid to click when Throttle is depressed. If Solenoid Clicks Solenoid should be replaced.

• If Solenoid does NOT click measure the voltage across the Small Terminals of the

Solenoid when the Throttle is depressed.

It should read the Battery voltage. If it reads the Battery voltage the Solenoid is bad. If it does not read the Battery voltage check Vehicle Wiring.

• Check the temperature of the Controller with a non-contact temperature sensor.

• Check the temperature of the Motor with a non-contact temperature sensor.

• Check the FNR Switch. Does the Switch feel the same when toggled from FWD to

Neutral to REV? If so check continuity of the Switch.

18

INSTALLATION/SERVICE MANUAL

TSX V2 TROUBLESHOOTING

FLASH

CODES

FLASH CODE

MESSAGE

2 - 2 Main

Solenoid

(Contactor)

DESCRIPTION

Solenoid Coil takes too much current.

2 - 3 Motor

2 - 4 Controller not pre-charging

High field resistance

Abnormally low voltage on the Controller between B+ and B-.

SOLUTION

• Check for loose Wires or a short across Small

Terminals on the Solenoid.

Replace main Solenoid.

• Check the Motor Field Wires

(F1 & F2) to ensure they are not loose or damaged.

• Motor may be damaged internally and need to be replaced.

• Clean and dry off the

Controller

HOW TO CHECK

• Check for loose Wires. If there is a Diode across the Solenoid check that it is not shorted.

• Test Solenoid by measuring resistance across the Small Terminals of the

Solenoid. The resistance should be greater than 48 OHMS.

• Visually check the Motor Cables by following the Cables from the terminals on the Motor to the Controller.

• Measure Motor resistance; from F1 to F2 on the Motor. It should be around 1 to 2

Ohms. If greater than 2 Ohms, the Motor has an issue and may need to be replaced.

• Visually check for debris or moisture on

Controller Terminals and Wires (There may be a short across the B+ and B- posts).

2 - 4 Controller not pre-charging

Cables /Controller

2 - 5 Accelerator

The Accelerator signal is out of range. This can be caused by a faulty connection or a defective Accelerator

Assembly

3 - 3 Internal

Internal Issue

• Check voltage

• Check all Wires connected to the Controller

Test Cables at the Controller

• Check Accelerator Wires,

Vehicle Module Harness and

Accelerator

• Check the voltage between B+ and B- on the Controller. It should equal the Battery

Pack Voltage.

• Check that the Wires are not damaged.

• Check that the B+ and Field Wires are not shor ted to t he Frame or each other.

• Check that no accessories (Light Kits,

Stereos, etc.) are using the Frame as a ground.

• Remove all Cables except B- from the

Controller.

• Tape Cables so they do not touch each other or the Vehicle Frame. Controller

Module Harness should remain plugged into the Controller.

• Move Run/Tow Switch to Run, Turn on Key

Switch, depress the throttle. If 2-4 Flash

Code returns replace the Controller.

• Otherwise there is a Wiring problem.

Reconnect Wires one at a time (Turn off

RUN/TOW Switch each time) until 2-4 Flash

Code returns. This will indicate where the

Wiring issue is located.

• Check Accelerator Wires and Connections.

• Measure the voltage between the main

B- and Pin # 2 (center pin) on the 3 pin

4WD connector in the Vehicle Module

Harness. The Voltage should start near 0V and move up to a maximum of 5V. If not replace Throttle Sensor. i.e. MCOR, ITS, etc.

Can NOT be serviced in the field. Return to dealer or contact SilverWolf Vehicles

19

INSTALLATION/SERVICE MANUAL

TSX V2 TROUBLESHOOTING

NON-FLASH CODE TROUBLESHOOTING

NON-FLASH CODE ERRORS. Note: The list below shows some possible issues when the Controller does not show a Flash Code

Error. These issues are mainly related to the Vehicle. Always check the Manufacturers Service Manual.

ISSUE

The Vehicle is moving slower than normal.

CAUSE

• Batteries are discharged

• Bad or damaged Motor

• Faulty Speed Sensor

• Faulty Throttle

• OTF programmer is locked at low speed

HOW TO CHECK

• Re-charge the Batteries

• Check Motor

• Unplug Speed Sensor

• Raise the Vehicle so all wheels are off the ground. Depress Throttle and look for green flash on OTF Programmer when the Throttle is almost completely depressed.

• Connect the OTF Programmer, unlock it and adjust to desired speed.

Note: Lock OTF Programmer before removing it or the settings may change.

Vehicle is shutting down.

• Check Vehicle Wiring for loose connections

• Check the OBC (On Board

Computer)

• Check the OBC by referring to the “OBC section” in the manufacturers service manual.

Os cilla tions or bumpy feel when driving.

Vehicle feels sluggish after driving for a while.

Faulty Controller

• Motor compatibility

• Battery Cables are undersized

• Controller malfunction

• Check that the Motor is on the recommended Motors list

• Upgrade the Power Cables to at least 4AWG.

• Use a Digital Multimeter set to Diode mode

• Remove all Wires and Cables on Controller

• Use “Controller Diode Test” Chart below to test the Controller

CONTROLLER DIODE TEST

BLACK

LEAD

RED

LEAD

VOLTAGE

B+

M

F1

F2

B+

B+

M 0.42V approx.

B0.42V approx.

B0.48V approx.

B0.48V approx.

F1 0.48V approx.

F2 0.48V approx.

ISSUE

OTF Knobs do not change the Controller settings.

CAUSE

• OTF is Locked

• OTF Connector

• OTF Faulty

OTF TROUBLESHOOTING

HOW TO CHECK

• Use Key to unlock OTF to adjust Controller settings.

• Check that the 8 Pin Connector on the OTF is plugged in to the SW

Vehicle Module Harness

• Replace OTF or return for service.

Settings are not changing

• OTF not locking in new settings

• After adjusting the knobs to the desired settings, move the OTF Key from the UNLOCK to the LOCK position. The LOCK position saves the current settings to the Controller. The OTF may now be unplugged and removed from the Vehicle.

20

ACCESSORIES

OTF “ON THE FLY” PROGRAMMER

RECOMMENDED

FOR OPTIMAL

PERFORMANCE

PART #

25-002

• Driver can adjust the Acceleration, Regeneration, and Top Speed of the vehicle in Real Time.

• Valet Lockout allows the owner to set and key-lock the operating behavior of the vehicle.

• Simple diagnostics

• Easy for the dealer/operator to diagnose the most common vehicle issues (low battery voltage, defective throttle, bad

FWD/REV switch, faulty key switch, etc.)

• Plug and Play installation

• Speed adjustability On the Fly from 8 to 25 mph

21

Limited Warranty

Madjax, warrants that the products sold to Customer by Madjax will be free from defect in materials and workmanship for a period two years (24 months), from the date of manufacture of the product, subject to the terms and conditions in this Limited Warranty.

If, during the applicable warranty period, (i) Madjax is advised in writing as to a defect in a Navitas product; (ii) such product is returned to a receiving point designated by Madjax; and (iii) an examination of such product discloses to Madjax’ reasonable satisfaction that such product is defective and such defect was not caused by accident, abuse, neglect, alteration, improper installation, lightning damage, submersion, short circuits due to improper handling, repair, improper testing or use contrary to any instruction issued by Madjax, Madjax will repair or replace the defective product at no cost to

Customer, except for transportation costs. Replacement shall mean furnishing the Customer with a new product equivalent to the defective product.

All defective products replaced by Madjax under this warranty shall become the property of Madjax and must be returned to Madjax properly packed to prevent physical damage.

Madjax does not warrant that any product is suitable for use in any particular application. Customer shall be responsible for evaluating the appropriateness of the use of any specific Madjax product for a particular application and shall specify such use at the time of the placement of any order for a Madjax product. Madjax shall be entitled to rely exclusively upon such representation in furnishing any product to Customer.

Warranty Limitations

The foregoing warranty constitutes Madjax’ exclusive Liability and the exclusive remedy of Customer for any breach of or any other nonconformity of the products covered by this warranty. This warranty is exclusive and in lieu of all other warranties. Madjax makes no warranty, expressed or implied or statutory including, without limitation, any warranty of merchantability or fitness for a particular purpose.

No representative, employee, distributor or dealer of Madjax has the authority to make or imply any warranty, representation, promise or agreement, which in any way varies the terms of this limited warranty.

The Madjax products sold to Customer are intended to be used only in the application specified by Customer to Madjax. Any other use renders the

Limited Warranty expressed herein and all implied warranties null & void and same are hereby excluded. Under no circumstances shall Madjax be liable to Customer or any third party for consequential, incidental, indirect, exemplary, special or other damages whether in an action based on contract, tort

(including negligence) or any other legal theory, arising out of or related to the products sold to Customer, including but not limited to lost profits or loss of business, even if Madjax is apprised of the likelihood of such damages occurring.

This limited warranty may not be changed, modified, limited or extended in scope except by a written agreement signed by Madjax and Customer.

Except as stated, any purported modification of this limited warranty shall be null and void.

2051 2nd AVE NE

Cairo, GA 39826

866-410-5297 www.mymadjax.com

advertisement

Was this manual useful for you? Yes No
Thank you for your participation!

* Your assessment is very important for improving the workof artificial intelligence, which forms the content of this project

Related manuals

Download PDF

advertisement