Download - 1010 Generic Golf Cart Rev I
-
8/16/2019 1010 Generic Golf Cart Rev I
1/8
1551 S. Vineyard Avenue
Ontario, CA 91761
(909) 923-1973
WIRING SCHEMATICS
GENERIC GOLF CART
-
8/16/2019 1010 Generic Golf Cart Rev I
2/8
GENERIC GOLF CART
Page 2 of 8
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 i nformation
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 anycomplete or partial reproduction of this drawing.
VISIO
12/02/10
11 H
1010-GNRC-001
GENERIC GOLF CAR SCHEMATIC
NONE
MAIN CONTACTOR(NOTE *4)
ORANGE/ WHITE 18 AWG
I/O GROUND
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 18 AWG
BLACK/ BLUE18 AWG
GREEN 18 AWG
WHITE/ RED 18 AWG
BLUE/ WHITE 18 AWG
YELLOW/ WHITE 18 AWG
YELLOW 18 AWG
RED 22 AWG
RED / WHITE 18 AWG
WHITE 22 AWG
GREEN 22 AWG
TAN 18 AWG
TAN/ BLACK 18 AWG
WHITE 18 AWG
MOTOR TEMP
N/C
N/C
N/C
N/C
N/C
N/C
GOLF / STREET SWITCH
MENU BUTTON
(NOTE *3)
YELLOW BLACK 18 AWG
FWD/ REV
(NOTE*2)
TAN 18 AWG
TAN/ BLACK 18 AWG
RED / WHITE 18 AWG
BLACK BLUE 18 AWG
BLACK/ BLUE 18 AWG
YELLOW/ BLACK 18 AWG
POT HIGH BLACK/ WHITE 18 AWG
POT LOW PURPLE/ WHITE 18 AWG
R3
MOLEX MINI FIT JR39-01-2080
RED 18AWG
10A
REV
FWD
BLUE 18 AWG
BLACK/ WHITE 18 AWG
PURPLE/ WHITE 18 AWG
GREEN 18 AWG
WHITE/ RED 18 AWG
YELLOW 18 AWG
WHITE 18 AWG
BLACK 22 AWG
RED 22 AWG
WHITE 22 AWG
GREEN 22 AWG
BRAKE SWITCH
BROWN 18 AWG
PURPLE 18 AWG
KEY SWITCH
A B
OFF
ON
S6
BRAKE RELAY
FEMALE3/16” QD MALE 3/16” Q D
N.C. PEDAL INTERLOCK
(SEE THROTTLE
SCHEMATICS)
ECONOMY MODE
FEMALE1/4” Q D MALE1/4” QD
MULTIPLECONDUCTOR
CABLES1
FEMALE
3/16” QD
BACK UP BUZZER
R1
AMP #776164-1
YELLOW/ WHITE 18 AWG
FEMALE3/16”
QD
UVW
B +B -
3 5 P I N
C ONNE C T OR
( S E E R1 )
A
B
MAIN BATTERY
PACK
+ -
1234 / 1236 / 1238
CONTROLLER
U
MOTOR
M O T O R E N C O D E R
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
A
1:1
DISPLAY6
5
8
1
W
V
+A1 -A2 87 30
85 86
ORANGE 18 AWG
N/C
TO BRAKE LIGHTS + 12 V
CHARGER
CHARGEROUTPUT
120V AC
CHARGER INPUT
B
A+48V OR +72V
-48V OR -72V
BACK UP BUZZER
GRAY 18 AWG
S2**
N/C
NOTES:
** SPLICES S2, S3 IS PERFORMED BY THE END CUSTOMER
(*1) BLACK AND WHITE NOT USED ON 2 WIRE POT. SELECT TYPE 3 PARAMENTER.
(*2) IF REVERSE IS NOT USED, CONNECT WHITE WIRE TO BLUE WIRE.
(*3) MENU BUTTON IS OPTIONAL USE WITH DISPLAY.
(*4) REMOVE ANY DIODES OR RESISTOR FROM MAIN CONTACTOR.
(*5) USE 400A FUSE IN 650 SYSTEM. USE 300A FUSE IN 350 SYSTEM.
(*6) NORMALLY OPEN. CONTACTS MUST BE CLOSED WHEN BRAKE PEDAL IS PRESSED.
(*7) MOTOR TEMP SENSOR NOT USED FOR GOLF CART APPLICATION.
PURPLE 18 AWG
BROWN 18 AWG
N/C
N/C
N/C
N/C
N/C
P4
DEUTSCH
DTM-04-4P
R4
DEUTSCH
DTM-06-4S
MOTOR
ENCODER
CABLE
BLACK/ BLUE 22 AWG
RED/ WHITE 22 AWG
TAN 22AWG
TAN/ BLACK 22 AWG
BLACK 22 AWG
PURPLE 22
AWG
R5
MOLEX SL
SERIES
50-57-9405
MOTOR TEMP
SENSOR
(NOTE *7)
1
2
3
4
5
BRAKE SWITCH (NOTE*6)
S3**
400A
(NOTE *5)
THROTTLE
(NOTE*1)
BRAKE LIGHT
RELAY
1
2
1
2
3
4
1
2
1
2
3
4
P4-2DEUTSCH
DTM-04-2P
R4-2
DEUTSCH
DTM-06-2S
DRW SIZE
APPLICABLE
SOFTWARE
CAD TYPE
UNIT DRAWING
TITTLE
SCALE
DATE
REVISIONSHEET HPEVSOF
SUPPLIER PART HW-1010-HPG
-
8/16/2019 1010 Generic Golf Cart Rev I
3/8
THROTTLE CONFIGURATION
Depending on the type of throttle used for the application, the different types of throttle
configurations are listed within the table below. Electrical schematics are also included within
the following pages.
THROTTLE CONFIGURATION TYPE
ELECTRONIC without SWITCH
or
3 WIRE with SWITCH 0-5kΩ
or
CURTIS PB8 THROTTLE ASSEMBLY
TYPE 2
2 WIRE with SWITCH 0-5kΩ TYPE 3
-
8/16/2019 1010 Generic Golf Cart Rev I
4/8
Page 4 of 8
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.
REV DESCRIPTION APPROVED
A INITIAL RELEASE 1/22/2013
REVISIONS
BLACK / BLUE (BLACK
IN 1239 CTRL)
YELLOW / WHITE
PURPLE / WHITE
** When Electronic pedal is used, the GREEN wire from
pedal interlock does not need to be connected
TYPE 2
ELECTRONIC
THROTTLE**GROUND
SIGNAL
+5V or +12V
ELECTRONIC
THROTTLE
1/22/13
1010-THROTTLE-001
NONE
ELECTRONIC THROTTLE
VISIO
44 B
NONE
ADRW SIZE
APPLICABLESOFTWARE
CAD TYPE
UNIT DRAWING
TITTLE
SCALE
DATE
REVISIONSHEET HPEVSOF
SUPPLIER PART
Pin #7*
Pin #16*
For 5V: Pin #26*
For 12V: Pin #25*
* Throttle connection, verify correct voltage and connection in
throttle documents.
Not all Electronic Throttles supported
-
8/16/2019 1010 Generic Golf Cart Rev I
5/8
Page 5 of 8
NOTICE: This drawing is the property of Hi Performance Electric Vehicle Systems I nc., 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.
REV DESCRIPTION APPROVED
A INITIAL RELEASE 1/22/2013
B REVISION 11/27/2013
REVISIONS
YELLOW / WHITE
PURPLE / WHITE
RED/ BLUE
GREEN
NORMALLY CLOSED
INTERLOCK SWITCH**
** When accelerator pedal IS PRESSED the interlock switchis released to its
NORMAL position (switch not activated)
thus completing the circuit since its green wire is connected
to the normally closed (NC) connection.
COM NC
2 WIRE TYPE 3
THROTTLE
POT LOW
WIPER
THROTTLE ASSEMBLY
1/22/13
1010-THROTTLE-001
NONE
3 WIRE TYPE 3
THROTTLE
VISIO
41 B
NONE
A
DRW SIZE
APPLICABLE
SOFTWARE
CAD TYPE
UNIT DRAWING
TITTLE
SCALE
DATE
REVISIONSHEET HPEVSOF
SUPPLIER PART
Pin #16
Pin #18
Pin #25
Pin #9
-
8/16/2019 1010 Generic Golf Cart Rev I
6/8
Page 6 of 8
1/22/13
1010-THROTTLE-001
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.
3 WIRE TYPE 3
THROTTLE
BLACK / WHITE
** When accelerator pedal IS PRESSED the interlock switchis released to its
NORMAL position (switch not activated)
thus completing the circuit since its green wire is connected
to the normally closed (NC) connection.
NC
3 WIRE TYPE 2
THROTTLE
POT HIGH
REV DESCRIPTION APPROVED
A INITIAL RELEASE 1/22/2013
B REVISION 11/27/2013
REVISIONS
YELLOW / WHITE
PURPLE / WHITE
RED/ BLUE
GREEN
NORMALLY CLOSED
INTERLOCK SWITCH**
COM
POT LOW
WIPER
THROTTLE ASSEMBLY
VISIO
42 B
NONE
A
DRW SIZE
APPLICABLE
SOFTWARE
CAD TYPE
UNIT DRAWING
TITTLE
SCALE
DATE
REVISIONSHEET HPEVSOF
SUPPLIER PART
Pin #25
Pin #15
Pin #16
Pin #18
Pin #9
-
8/16/2019 1010 Generic Golf Cart Rev I
7/8
Page 7 of 8
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.
BLACK / WHITE
** When the accelerator pedal IS PRESSED the interlock
switch is released to its NORMAL position (switch not
activated) thus completing the circuit since its green wire is
connected to the normally closed (NC) connection.
NC
CURTIS PB8
THROTTLE
ASSEMBLY
POT HIGH
REV DESCRIPTION APPROVED
A INITIAL RELEASE 11/27/2013
REVISIONS
YELLOW / WHITE
PURPLE / WHITE
RED/ BLUE
GREEN
NORMALLY CLOSED
INTERLOCK SWITCH**
COM
POT LOW
WIPER
WHITE
BLACK
THROTTLE ASSEMBLYRED
1/22/13
1010-THROTTLE-001
NONE
CURTIS PB8
THROTTLE ASSEMBLY
VISIO
43 A
NONE
A
DRW SIZE
APPLICABLE
SOFTWARE
CAD TYPE
UNIT DRAWING
TITTLE
SCALE
DATE
REVISIONSHEET HPEVSOF
SUPPLIER PART
Pin #25
Pin #15
Pin #16
Pin #18
Pin #9
-
8/16/2019 1010 Generic Golf Cart Rev I
8/8
Page 8 of 8
PEDAL INTERLOCK CONNECTION
The pedal interlock connection is required for both 2 and 3 wire throttle pot assemblies. The Green wire is connected to the
Normally Closed tab. The red/blue wire is connected to the common tab. See picture below.
NOTE: when the accelerator pedal IS PRESSED the interlock switch is released to its NORMAL position (switch not activated) thus
completing the circuit since its green wire is connected to the normally closed (NC) connection.