NAVITAS Vehicle Systems Ltd.
NAVITAS 440A-600A
FOR SHUNT WOUND AND SERIES DC MOTOR CONTROLLER
Installation/Service Manual
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
Yamaha Drive with Moric Controller JW2
Also compatible with:
Curtis 1520, 1268 (Resistive Throttle)
Curtis 1264, 1268 (ITS Throttle) ITS E-Z-GO 48V
Yamaha G19/G22
This manual is available online at NavitasVS.com
06-11-19
NavitasVS.com
Qty. 4000
VEHICLE SYSTEMS LTD.
Please refer to Navitas online manuals
and installation videos for the most
up-to-date install information;
www.navitasvs.com/manuals
Copyright © 2019
Navitas Vehicle Systems Ltd. All Rights Reserved. Patents Pending. E-Z-GO®, TXT®, and
RXV® are registered trademarks of Textron Innovations, Inc. (“Textron”). Club Car®,
Precedent®, and DS® are registered trademarks of Ingersoll Rand, Inc., Yamaha®,
the tuning fork logo, G-14®, G-19®, G-22®, G-24®, G-29®, and Drive® are registered
trademarks of the Yamaha Golf Car Company (“Yamaha”). References to E-Z-GO®,
Club Car®, Yamaha®, or other manufacturers on this manual or any associated
electronic or printed publication are solely for purposes of identifying golf carts.
INSTALLATION/ SERVICE MANUAL
TABLE OF CONTENTS
BEST PRACTICES ..............................................................................................................................................................3
INTRODUCTION ...............................................................................................................................................................4
Serial # Record Form ....................................................................................................................................................................... 4
WARNINGS ......................................................................................................................................................................5
Safety /Installation Warnings .................................................................................................................................................. 5
PARTS LIST .............................................................................................................................................................. 6
INSTALLATION INSTRUCTIONS – ALL CARS .....................................................................................................................7
Wire Identification & Location .................................................................................................................................................................. 8
INSTALLATION INSTRUCTIONS- CLUB CAR® PRECEDENT 48V ...........................................................................................9
INSTALLATION INSTRUCTIONS- E-Z-GO® TXT 48V ........................................................................................................... 11
INSTALLATION INSTRUCTIONS- E-Z-GO® TXT 36V ........................................................................................................... 13
INSTALLATION INSTRUCTIONS- YAMAHA® G19/G22 48V ............................................................................................... 15
INSTALLATION INSTRUCTIONS- YAMAHA® DRIVE 48V....................................................................................................19
INSTALLATION INSTRUCTIONS NAVITAS Par Car 48V ....................................................................................................... 21
INSTALLATION INSTRUCTIONS NAVITAS SERIES 36-48V ..................................................................................................... 24
Controller Mounting –SERIES Install Locations ......................................................................................................................25
INSTALLATION INSTRUCTIONS – SERIES CLUB CAR & E-Z-GO® .......................................................................................26
CONTROLLER TEST INSTRUCTIONS .................................................................................................................................29
Controller Pre-Drive Test....................................................................................................................................................................................29
Controller Drive Test ..................................................................................................................................................................................................... 29
TROUBLESHOOTING (all systems) .................................................................................................................................. 30
Preliminary Troubleshooting.................................................................................................................................................31
Flash Code Legend ................................................................................................................................................................................... 31
Flash Code Chart ...................................................................................................................................................................................... 32
Non-Flash Code Troubleshooting............................................................................................................................................................ 34
Controller Diode Test Chart .................................................................................................................................................................... 34
ACCESSORIES ........................................................................................................................................................ 35
Bluetooth® Apps for TSX 3.0 .................................................................................................................................................................. 35
APPENDICES .........................................................................................................................................................................................................36
Appendix A - Pinout for Club Car® IQ - SHUNT...........................................................................................................................................................36
Appendix B - Pinout for E-Z-GO® TXT - SHUNT .......................................................................................................................................... 37
Appendix C - Pinout for YAMAHA® G19/22 (MORIC) Controller.............................................................................................................................38
Appendix D - Pinout for Yamaha® Drive® - SHUNT ...................................................................................................................................................39
Appendix E - Pinout for Par Car®- SHUNT.................................................................................................................................................. 40
Appendix F - Pinout for Club Car®- SERIES................................................................................................................................................. 41
Appendix G- Pinout for E-Z-GO®- SERIES .................................................................................................................................................................... 42
Warranty................................................................................................................................................................................................... 43
2
3
INSTALLATION/ SERVICE MANUAL
INTRODUCTION
NAVITAS TSX 3.0 440A 36-48V Controller &
TSX 3.0 600A 36-48V Controller
SERIES & SHUNT WOUND 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.
Navitas Vehicle Systems Ltd. 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.
Navitas Vehicle Systems Ltd. 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
SERIAL #
10-000685 TSX 3.0 600A 36-48V CONTROLLER(w/BT)
10-000766 TSX 3.0 440A 36-48V CONTROLLER (w/BT)
4
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5ϱ
INSTALLATION/SERVICE MANUAL
CONTROLLER PARTS LIST
Confirm that all parts listed below are with your kit before starting installation. This kit includes either the TSX 3.0 440A 36-48V
Controller or the TSX 3.0 600A 36-48V Controller. If you are missing parts, please contact your local dealer.
PART DESCRIPTION
1 TSX 3.0 600A 36-48V Controller
PART #
QTY
10-000685
1
3 M8 X 16 Hex Cap 8.8 Zinc (Not Shown)
10-000766
80-000901
3
4 M6 X 16 Hex Cap 8.8 Zinc (Not Shown)
80-000902
2
5 M8 Lock Washer (Not Shown)
80-000910
3
6 M6 Lock Washer (Not Shown)
80-000909
2
7 M8 Flat Washer (Not Shown)
80-000888
3
8 M6 Flat Washer (Not Shown)
80-000889
2
9 Spade Connector 6.3MM - for Club Car Precedent & DS, E-Z-GO TXT
Yamaha
(pre-installed
on controller)
(Not Shown)
10 36V
2 AWG
5/16”Drive
Ring Terminal
(Yamaha
Drive Only!)
20-001010
2
40-000536
1
11 Optional DC Hardware Kit for E-Z-Go
10-000770
2 TSX 3.0 440A 36-48V Controller
1
9
Harness
WIRING PARTS LIST
This kit includes only one of the Harnesses listed below. Note: some Harnesses look similar.
Make sure to check the part number and description label on the bottom of the Harness before connecting to the Controller.
PART DESCRIPTION
PART #
40-000542
QTY
1* Harness for Curtis 1206MX Controller (E-Z-GO TXT 36V)
1* Harness for Curtis 1206HB Controller (E-Z-GO TXT 48V)
40-000512
1
40-000541
1
1* Harness for Moric JW2 Controller(Yamaha Drive)
40-000513
1
1* Harness for Yamaha G19/G22
40-000514
1
1* Harness for Curtis 1520, 1268 (Resistive Throttle)
40-000515
1
1* Harness for Curtis 1264, 1268 (ITS Throttle) ITS E-Z-GO 48V
40-000516
1
1* Harness for DCS 36V Controller (E-Z-GO TXT DCS 36V)
40-000540
1
1* Harness for Curtis 1510/1515 Controller (Club Car Precedent & DS)
6
6
1
7
INSTALLATION/ SERVICE MANUAL
INSTALLATION INSTRUCTIONS
Wire & Connector Location Diagram
440A 36-48V & 600A 36-48V Controller-Harness
Connector Plug Location
1 Vehicle 16 Pin Vehicle Harness
Connector
“On The Fly” Programmer
2 OTF
8 Pin
*(Optional) Not included
Not Used
3 Reserved 3 Pin
NOTE: The harness should be
oriented and secured with
Zip Ties to prevent water and
debris from accumulating in
the connectors
This Mot
Rating),
specifica
2
1
*This Label m
3
440A 36-48V & 600A 36-48V Controller- Wire Location
Status
Light
F2
B-
M
B+
F1
F1
FIELD WIRE
B-
MAIN BATTERY
NEGATIVE
M
MOTOR
B+
MAIN BATTERY
POSITIVE
F2
FIELD WIRE
Field Switch Wire
BLACK Negative Cable from
Battery.
RED Positive Cable from
Battery.
Field Switch Wire
NOTE: if F1 & F2 Field Wires are installed incorrectly, then
FWD/REV will work in the opposite direction.
The NAVITAS 440A 36-48V & 600A 36-48V Controllers have 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.
Torque Specifications
F1 & F2
6 mm Bolt 60 in-lbs/ 5ftlbs/ 6.8Nm
B-/M/B+ 8 mm Bolt 150 in-lbs/ 12.5ftlbs/ 16.9Nm
88
G
from the solenoid
9
E
C
D
F
INSTALLATION/ SERVICE MANUAL
INSTALLATION INSTRUCTIONS
Club Car Precedent with Curtis 1510/1515 Installation cont’d.
G
E
C
D
F
(H) Install the 20 Pin Connector on the Vehicle Module Harness to the Controller. Note: The plastic around this plug may need to be
cut away to allow for the Body Cover to be re-installed. See the Cut Out instructions below if harness cannot be inserted properly
(I) Install the 16 Pin Connector from the Vehicle Wiring Harness to the 16 Pin Connector on the New Navitas Vehicle Module Harness.
(J) This Connector is NOT USED.
(K) This 8 Pin Connector is for the optional OTF “On The Fly” Programmer.
*There is a 4 Pin Connector on the Vehicle Harness that is used for the Club Car Programmer. This 4 Pin Connector is not
used on the NAVITAS Controller and will be left unplugged.
10
Now the Vehicle’s Main Battery Positive and Negative Cables can be re-connected.
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ƚŚĂƚƚŚĞŐƌŽƵƉƐŽĨǁŝƌĞƐƐƚĂLJƚŽŐĞƚŚĞƌ͘
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;ϭͿZĞŵŽǀĞƉƌĞͲĐŚĂƌŐĞƌĞƐŝƐƚŽƌĨƌŽŵĐŽŶƚĂĐƚŽƌĂŶĚĚŝƐĐĂƌĚ͘
;Ϳ/ŶƐƚĂůůƚŚĞŽŶƚƌŽůůĞƌƵƐŝŶŐƚŚĞϯƐĐƌĞǁƐ ĨƌŽŵƚŚĞŽƌŝŐŝŶĂůĐŽŶƚƌŽůůĞƌ͘
;ͿŽŶŶĞĐƚƚŚĞDŽƚŽƌĂďůĞĨƌŽŵƚŚĞŽƌŝŐŝŶĂůŽŶƚƌŽůůĞƌƚŽƚŚĞDdĞƌŵŝŶĂůŽŶƚ ŚĞŽŶƚƌŽůůĞƌƵƐŝŶŐĂDϴŽůƚ͕>ŽĐŬtĂƐŚĞƌĂŶĚ&ůĂƚtĂƐŚĞƌ͘
;Ϳ ŽŶŶĞĐƚ ƚŚĞ DĂŝŶ WŽƐŝƚŝǀĞ ZĞĚ WŽǁĞƌ ĂďůĞ ƚŽ ƚŚĞ н dĞƌŵŝŶĂů ŽŶƚŚĞ ŽŶƚƌŽůůĞƌƵƐŝŶŐĂDϴŽůƚ͕>ŽĐŬtĂƐŚĞƌ ĂŶĚ&ůĂƚ tĂƐŚĞƌ͘
;ͿŽŶŶĞĐƚƚŚĞDĂŝŶEĞŐĂƚŝǀĞůĂĐŬWŽǁĞƌĂďůĞƚŽƚŚĞͲd ĞƌŵŝŶĂůŽŶƚŚĞŽŶƚƌŽůůĞƌƵƐŝŶŐĂDϴŽůƚ͕>ŽĐŬtĂƐŚĞƌĂŶĚ&ůĂƚtĂƐŚĞƌ͘
;&Ϳ/ŶƐƚĂůůƚŚĞ&ϭ&ŝĞůĚtŝƌĞĨƌŽŵƚŚĞŽƌŝŐŝŶĂůŽŶƚƌŽůůĞƌƚŽƚŚĞ&ϭd ĞƌŵŝŶĂůŽŶƚŚĞŽŶƚƌŽůůĞƌ ƵƐŝŶŐĂ^ƉĂĚĞŽŶŶĞĐƚŽƌ͘;'Ϳ/ŶƐƚĂůůƚŚĞ
&Ϯ&ŝĞůĚtŝƌĞĨƌŽŵƚŚĞŽƌŝŐŝŶĂůŽŶƚƌŽůůĞƌƚŽƚŚĞ&ϮdĞƌŵŝŶĂůŽŶƚŚĞŽŶƚƌŽůůĞƌdĞƌŵŝŶĂůƵƐŝŶŐĂ^ƉĂĚĞŽŶŶĞĐƚŽƌ͘
ϲŵŵŽůƚ ϲϬŝŶͲůďƐͬ ϱĨƚůďƐͬϲ͘ϴEŵ
ͲͬDͬн ϴŵŵŽůƚ ϭϱϬŝŶͲůďƐͬϭϮ͘ϱĨƚůďƐͬ ϭϲ͘ϵEŵ
WƌĞͲŚĂƌŐĞZĞƐŝƐƚŽƌ
11
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;'Ϳ/ŶƐƚĂůůƚŚĞϮϬWŝŶŽŶŶĞĐƚŽƌŽŶƚŚĞŶĞǁEĂǀŝƚĂƐ,ĂƌŶĞƐƐƚŽƚŚĞŽŶƚƌŽůůĞƌ͘
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ƌŽŵƚƚŚĞ
ŚĞssĞŚŝĐůĞ
ĞŚŝĐůĞt
tŝƌŝŶŐ
ŝƌŝŶŐ,,ĂƌŶĞƐƐ
ĂƌŶĞƐƐƚƚŽ
ŽƚƚŚĞ
ŚĞϭϭϲ
ϲWWŝŶ&ĞŵĂůĞŽŶŶĞĐƚŽƌ
ŝŶ&ĞŵĂůĞŽŶŶĞĐƚŽƌŽŽŶ
ŶƚƚŚĞEĞǁEĂǀŝƚĂƐ
ŚĞEĞǁEĂǀŝƚĂƐ,,ĂƌŶĞƐƐ͘
ĂƌŶĞƐƐ͘
Male
Connector ĨĨƌŽŵ
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EKd͗dŚĞEĞǁEĂǀŝƚĂƐ,ĂƌŶĞƐƐƐŚŽƵůĚďĞŽƌŝĞŶƚĞĚĂŶĚƐĞĐƵƌĞĚǁŝƚŚŝƉdŝĞƐƚŽƉƌĞǀĞŶƚǁŝƌĞĚĂŵĂŐĞ͘and to prevent water
from collecting in the molex connectors.
KWd/KE>,ĂƌĚǁĂƌĞ<ŝƚǀĂŝůĂďůĞ͗
KWd/KE>,ĂƌĚǁĂƌĞ<ŝƚǀĂŝůĂďůĞ͗ŽŶƚĂĐƚŽƌƐƚĂŶĚŽĨĨďŽůƚƐĨŽƌ/ŶƐƚĂůůǁŝƚŚůĂƌŐĞƌŽŶƚĂĐƚŽƌ
ŽŶƚĂĐƚŽƌƐƚĂŶĚŽĨĨďŽůƚƐĨŽƌ/ŶƐƚĂůůǁŝƚŚůĂƌŐĞƌŽŶƚĂĐƚŽƌΘZƵŶͬdŽǁ
ΘZƵŶͬdŽǁ^ǁŝƚĐŚDŽƵŶƚ
^ǁŝƚĐŚDŽƵŶƚ
EŽǁƚŚĞsĞŚŝĐůĞ͛ƐDĂŝŶĂƚƚĞƌLJWŽƐŝƚŝǀĞĂŶĚEĞŐĂƚŝǀĞĂďůĞƐĐĂŶďĞƌĞͲĐŽŶŶĞĐƚĞĚ
EŽǁƚŚĞsĞŚŝĐůĞ͛ƐDĂŝŶĂƚƚĞƌLJWŽƐŝƚŝǀĞĂŶĚEĞŐĂƚŝǀĞĂďůĞƐĐĂŶďĞƌĞͲĐŽŶŶĞĐƚĞĚƚŽĂƚƚĞƌLJWĂĐŬ͘
ƚŽĂƚƚĞƌLJWĂĐŬ͘
EŽƚĞ͗dŽƌƋƵĞĂůůďĂƚƚĞƌLJƚĞƌŵŝŶĂůƐƚŽϵϬŝŶͲůďƐ͘
EŽƚĞ͗dŽƌƋƵĞĂůůďĂƚƚĞƌLJƚĞƌŵŝŶĂůƐƚŽϵϬŝŶͲůďƐ͘
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12
INSTALLATION/ SERVICE MANUAL
INSTALLATION INSTRUCTIONS
E-Z-GO TXT 36V with Curtis 1206MX Installation
This Mot
Rating),
specifica
•
FAILURE to follow the WARNINGS below can damage
the•Vehicle and/or cause SERIOUS INJURY OR DEATH!
*This Label m
Before removing the original Controller take note or take a photo of the 5 Controller Terminals and their corresponding Wires. Make sure
that the groups of cables and 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
(A1) Remove pre-charge resistor from contactor and discard (refer to part photo on p 11)
(B) Install the 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. If not, use a 1/4 in. – 20 bottoming tap to attach.
A
C
A
B
Torque Specifications
F1 & F2
6 mm Bolt 60 in-lbs/ 5ftlbs/ 6.8Nm
B-/M/B+ 8 mm Bolt 150 in-lbs/ 12.5ftlbs/ 16.9Nm
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
5
3 Vehicle 4 Pin Vehicle Harness Connector
1
2
4 Vehicle 10 Pin Vehicle Harness Connector
6
5 Reserved 3 Pin NOT USED
6 OTF
8 Pin
3
“On The Fly” Programmer
*(Optional) Not included
13
13
4
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;ͿŽŶŶĞĐƚƚŚĞDĂŝŶWŽƐŝƚŝǀĞZĞĚWŽǁĞƌ ĂďůĞĨƌŽŵƚŚĞs ĞŚŝĐůĞ^ŽůĞŶŽŝĚƚŽƚŚĞнdĞƌŵŝŶĂůŽŶƚ ŚĞŽŶƚƌŽůůĞƌƵƐŝŶŐĂDϴŽůƚ͕>ŽĐŬ
tĂƐŚĞƌĂŶĚ&ůĂƚtĂƐŚĞƌ͘
;&ͿŽŶŶĞĐƚƚŚĞDĂŝŶEĞŐĂƚŝǀĞůĂĐŬWŽǁĞƌĂďůĞƚŽƚŚĞͲdĞƌŵŝŶĂůŽŶƚŚĞŽŶƚƌŽůůĞƌƵƐŝŶŐĂDϴŽůƚ͕> ŽĐŬtĂƐŚĞƌĂŶĚ&ůĂƚtĂƐŚĞƌ͘
;'Ϳ/ŶƐƚĂůůƚŚĞ&ϭ&ŝĞůĚtŝƌĞ;ƵƐƵĂůůLJŐƌĞĞŶͿĨƌŽŵƚŚĞŽƌŝŐŝŶĂůŽŶƚƌŽůůĞƌƚŽƚŚĞ&ϭdĞƌŵŝŶĂůŽŶƚŚĞŽŶƚƌŽůůĞƌƵƐŝŶŐĂ^ƉĂĚĞŽŶŶĞĐƚŽƌ͘
;,Ϳ/ŶƐƚĂůůƚŚĞ&Ϯ&ŝĞůĚtŝƌĞ;ƵƐƵĂůůLJďůĂĐŬͿ ĨƌŽŵƚŚĞŽƌŝŐŝŶĂůŽŶƚƌŽůůĞƌƚŽƚŚĞ&ϮdĞƌŵŝŶĂůŽŶ ƚŚĞ ŽŶƚƌŽůůĞƌdĞƌŵŝŶĂůƵƐŝŶŐĂ^ƉĂĚĞ
ŽŶŶĞĐƚŽƌ͘
KƉƚŝŽŶĂů<ŝƚ͗
ZƵŶͬdŽǁ
^ǁŝƚĐŚƌĂĐŬĞƚ
;^ĞĞƉĂŐĞϲͿ
^ĞĞƚŚĞ͞KEEdKZW>h'>Kd/KE͟ŚĂƌƚŽŶƚŚĞƉƌĞǀŝŽƵƐƉĂŐĞĂŶĚƉŚŽƚŽĂďŽǀĞƚŽĐŽŶŶĞĐƚƚŚĞsĞŚŝĐůĞŽŶŶĞĐƚŽƌƐƚŽƚŚĞ,ĂƌŶĞƐƐ͘
;/Ϳ/ŶƐƚĂůůƚŚĞϮϬWŝŶŽŶŶĞĐƚŽƌŽŶƚŚĞ,ĂƌŶĞƐƐƚŽƚŚĞŽŶƚƌŽůůĞƌ͘
;:Ϳ /ŶƐƚĂůůƚŚĞŽŶŶĞĐƚŽƌƐĨƌŽŵƚŚĞsĞŚŝĐůĞtŝƌŝŶŐ,ĂƌŶĞƐƐƚŽƚŚĞŽŶŶĞĐƚŽƌƐŽŶƚŚĞE Ğǁ E Ăǀŝƚ ĂƐ,ĂƌŶĞƐƐĂƐƐŚŽǁŶŝŶƚŚĞ
͞KEEdKZ W>h' >Kd/KE͟ ŚĂƌƚŽŶƚŚĞ ƉƌĞǀŝŽƵƐƉĂŐĞ͘
EKd͗dŚĞDŽĚƵůĞƐŚŽƵůĚďĞŽƌŝĞŶƚĞĚĂŶĚƐĞĐƵƌĞĚǁŝƚŚŝƉdŝĞƐƚŽƉƌĞǀĞŶƚǁŝƌĞĚĂŵĂŐĞ͘
;<Ϳ/ĨƌĞͲŝŶƐƚĂůůŝŶŐƚŚĞŽŶƚƌŽůůĞƌŽǀĞƌǁŝƚŚƚŚĞZhEͬdKt^ǁŝƚĐŚƚŚĞŽǀĞƌ͕ǁŝůůŶĞĞĚƚŽďĞĐƵƚŽĨĨĂƚƚŚĞďŽƚƚŽŵďĞĐĂƵƐĞŽĨƚŚĞŶĞǁ
^ŽůĞŶŽŝĚůŽĐĂƚŝŽŶ͘hƐĞĂ^ĂǁƚŽĐƵƚƚŚĞďŽƚƚŽŵϮ͛͟ƐŽĨƚŚĞŽǀĞƌ͘WůƵŐŝŶƚŚĞϰƉŝŶŽŶŶĞĐƚŽƌĨƌŽŵƚŚĞZhEͬdKt^ǁŝƚĐŚƚŽƚŚĞ,ĂƌŶĞƐƐ
ĂŶĚƌĞŝŶƐƚĂůůƚŚĞŽŶƚƌŽůůĞƌŽǀĞƌ͘ NOTE: The harness should be oriented and secured with Zip
EKd͗dŚĞ,ĂƌŶĞƐƐƐŚŽƵůĚďĞŽƌŝĞŶƚĞĚĂŶĚƐĞĐƵƌĞĚǁŝƚŚŝƉdŝĞƐƚŽƉƌĞǀĞŶƚǁŝƌĞĚĂŵĂŐĞ͘
Ties to prevent water and debris from accumulating in the
connectors
EŽǁƚŚĞsĞŚŝĐůĞ͛ƐDĂŝŶĂƚƚĞƌLJ WŽƐŝƚŝǀĞĂŶĚEĞŐĂƚŝǀĞĂďůĞƐĐĂŶďĞƌĞͲĐŽŶŶĞĐƚĞĚ͘
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14
INSTALLATION/ SERVICE MANUAL
/ E ^ d >> d/ K E ͬ ^ Zs / DEh>
INSTALLATION INSTRUCTIONS
/E^d>>d/KE
/E^dZhd/KE^
YAMAHA
G19/22 Installation
(GE and MORIC)
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ĞĨŽƌĞƌĞŵŽǀŝŶŐƚŚĞŽƌŝŐŝŶĂůŽŶƚƌŽůůĞƌ ƚĂŬĞŶŽƚĞŽƌƚĂŬĞĂƉŚŽƚŽŽĨƚŚĞϱŽŶƚƌŽůůĞƌdĞƌŵŝŶĂůƐĂŶĚƚŚĞŝƌĐŽƌƌĞƐƉŽŶĚŝŶŐtŝƌĞƐ͘DĂŬĞƐƵƌĞ
ƚŚĂƚƚŚĞŐƌŽƵƉƐŽĨǁŝƌĞƐƐƚĂLJƚŽŐĞƚŚĞƌ͘
ZĞŵŽǀĞ;ͿƚŚĞKƌŝŐŝŶĂůsĞŚŝĐůĞŽŶƚƌŽůůĞƌ͘;Ϳ/ŶƐƚĂůůƚŚĞŽŶƚƌŽůůĞƌƵƐŝŶŐƚŚĞϯƐĐƌĞǁƐĨƌŽŵ ƚŚĞŽƌŝŐŝŶĂůĐŽŶƚƌŽůůĞƌ͘
hd/KE͗ KEKd KEEd Ez t/Z^ KZ >^ hEd/> &dZ ^dW ͘
Which
Controller does your car have? Determine which controller is presently installed in
your car, the GE 2001-2004.5 Lowside Drive, or the
Moric 2004.5-2007 Highside Drive (pictured left and
right respectively in fig. 1), then follow the appropriate
directions below.
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fig. 1
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>ŽĐĂƚĞ;ͿƚŚĞzĐĂďůĞŽŶƚŚĞsĞŚŝĐůĞ,ĂƌŶĞƐƐ͗ƐŚŽǁŶĂƐϮŝŶƚŚĞƉŚŽƚŽďĞůŽǁ͘dŚŝƐĐĂďůĞĐŽŶƐŝƐƚƐŽĨϮĐĂďůĞƐĐƌŝŵƉĞĚƚŽŐĞƚŚĞƌŝŶƚŽ
<DPDKD'ULYH ZLWK0RULF-:,QVWDOODWLRQ
ĂZŝŶŐdĞƌŵŝŶĂů͘dŚĞŽŶĞƐŝĚĞĐŽŵĞƐĨƌŽŵƚŚĞĂƚƚĞƌLJEĞŐĂƚŝǀĞĂŶĚƚŚĞŽƚŚĞƌƐŝĚĞĐŽŵĞƐĨƌŽŵ
ƚŚĞϮŽŶƚŚĞDŽƚŽƌ͘hƐĞĂƉĂŝƌŽĨƐŝĚĞ
ĐƵƚƚĞƌƐƚŽĐƵƚƚŚĞϮƐŝĚĞŽĨƚŚĞĐĂďůĞĂƚƚŚĞZŝŶŐdĞƌŵŝŶĂů͘dŚĞŶĐƌŝŵƉŽŶĂŶĞǁƌŝŶŐƚĞƌŵŝŶĂů
;ŝŶĐůƵĚĞĚŝŶƚŚĞ,ĂƌŶĞƐƐďĂŐͿ͘EKd͗
ͻ
ŶĞǁ
,ĂƌŶĞƐƐƚŽďĞĐŽŶŶĞĐƚĞĚƚŽƚŚĞ
dŚĞZŝŶŐdĞƌŵŝŶĂůƐŽŶƚŚĞŽƌŝŐŝŶĂů,ĂƌŶĞƐƐŵĂLJŶĞĞĚƚŽďĞĚƌŝůůĞĚŽƵƚƚŽϱͬϭϲ͟ƚŽĂůůŽǁƚŚĞEĞǁ
ͻ
dŽƌƋƵĞ^ƉĞĐŝĨŝĐĂƚŝŽŶƐ
ŽŶƚƌŽůůĞƌ͘
YAMAHA G19/22 Installation (GE)
1.
If pre-charge
resistor is present, then remove
&ϭΘ&Ϯ ϲŵŵŽůƚ ϲϬŝŶͲůďƐͬ ϱĨƚůďƐͬϲ͘ϴEŵ
ĞĨŽƌĞƌĞŵŽǀŝŶŐƚŚĞŽƌŝŐŝŶĂůŽŶƚƌŽůůĞƌ ƚĂŬĞŶŽƚĞŽƌƚĂŬĞĂƉŚŽƚŽŽĨƚŚĞϱŽŶƚƌŽůůĞƌdĞƌŵŝŶĂůƐĂŶĚƚŚĞŝƌĐŽƌƌĞƐƉŽŶĚŝŶŐtŝƌĞƐ͘DĂŬĞƐƵƌĞ
and discardƚŚĂƚƚŚĞŐƌŽƵƉƐŽĨǁŝƌĞƐƐƚĂLJƚŽŐĞƚŚĞƌ͘
2.
Remove GEhd/KE͗
OEM Controller
KEKd KEEd Ez t/Z^ KZ >^ hEd/> &dZ ^dW ͘
3.
ͲͬDͬн ϴŵŵŽůƚ ϭϱϬŝŶͲůďƐͬϭϮ͘ϱĨƚůďƐͬ ϭϲ͘ϵEŵ
ZĞŵŽǀĞ;ͿƚŚĞKƌŝŐŝŶĂůsĞŚŝĐůĞŽŶƚƌŽůůĞƌ͘;Ϳ/ŶƐƚĂůůƚŚĞŽŶƚƌŽůůĞƌƵƐŝŶŐƚŚĞϯƐĐƌĞǁƐĨƌŽŵ ƚŚĞŽƌŝŐŝŶĂůĐŽŶƚƌŽůůĞƌ͘
Install the new TSX 3.0 controller (TSX)
4.
Connect A2 to M post using a M8 Bolt, Lock
Washer and Flat Washer
5.
Connect both A1 and Main Positive (B+) to
the B+ post using a M8 Bolt, Lock Washer
and Flat Washer
6.
Connect Main Negative( B-) to B- using a M8
A2
A1
Bolt, Lock >ŽĐĂƚĞ;ͿƚŚĞzĐĂďůĞŽŶƚŚĞsĞŚŝĐůĞ,ĂƌŶĞƐƐ͗ƐŚŽǁŶĂƐϮŝŶƚŚĞƉŚŽƚŽďĞůŽǁ͘dŚŝƐĐĂďůĞĐŽŶƐŝƐƚƐŽĨϮĐĂďůĞƐĐƌŝŵƉĞĚƚŽŐĞƚŚĞƌŝŶƚŽ
Washer
^ W,KdKKE&K>>Kt/E'
W' and Flat Washer
ĂZŝŶŐdĞƌŵŝŶĂů͘dŚĞŽŶĞƐŝĚĞĐŽŵĞƐĨƌŽŵƚŚĞĂƚƚĞƌLJEĞŐĂƚŝǀĞĂŶĚƚŚĞŽƚŚĞƌƐŝĚĞĐŽŵĞƐĨƌŽŵ
ƚŚĞϮŽŶƚŚĞDŽƚŽƌ͘hƐĞĂƉĂŝƌŽĨƐŝĚĞ
;ͿŽŶŶĞĐƚƚŚĞDŽƚŽƌĂďůĞ;ƵƐƵĂůůLJǁŚŝƚĞͿ
ĨƌŽŵƚŚĞŽƌŝŐŝŶĂůŽŶƚƌŽůůĞƌƚ Žƚ ŚĞDdĞƌŵŝŶĂůƐŽŶƚŚĞŽŶƚƌŽůůĞƌƵƐŝŶŐĂDϴŽůƚ͕>ŽĐŬ
7.
Connect
F1
from
OEM Controller to F1
fig. 2
ĐƵƚƚĞƌƐƚŽĐƵƚƚŚĞϮƐŝĚĞŽĨƚŚĞĐĂďůĞĂƚƚŚĞZŝŶŐdĞƌŵŝŶĂů͘dŚĞŶĐƌŝŵƉŽŶĂŶĞǁƌŝŶŐƚĞƌŵŝŶĂů
;ŝŶĐůƵĚĞĚŝŶƚŚĞ,ĂƌŶĞƐƐďĂŐͿ͘EKd͗
tĂƐŚĞƌĂŶĚ&ůĂƚtĂƐŚĞƌ͘
dŚĞZŝŶŐdĞƌŵŝŶĂůƐŽŶƚŚĞŽƌŝŐŝŶĂů,ĂƌŶĞƐƐŵĂLJŶĞĞĚƚŽďĞĚƌŝůůĞĚŽƵƚƚŽϱͬϭϲ͟ƚŽĂůůŽǁƚŚĞEĞǁ ,ĂƌŶĞƐƐƚŽďĞĐŽŶŶĞĐƚĞĚƚŽƚŚĞŶĞǁ
terminal using spade connector
;Ϳ ŽŶŶĞĐƚƚŚĞDĂŝŶWŽƐŝƚŝǀĞZĞĚWŽǁĞƌ
ĂďůĞĨƌŽŵƚ ŚĞsĞŚŝĐůĞ^ŽůĞŶŽŝĚ
ĂŶĚƚŚĞůĂĐŬϮĂďůĞ;ĂďůĞ
ƚ ŚĂƚǁ ĂƐĐƵƚĂŶĚŚĂƐƚŚĞEĞǁZŝŶŐ
ŽŶƚƌŽůůĞƌ͘
dŽƌƋƵĞ^ƉĞĐŝĨŝĐĂƚŝŽŶƐ
tĂƐŚĞƌ͘
dĞƌŵŝŶĂůͿƚŽƚŚĞнdĞƌŵŝŶĂůƐŽŶƚŚĞŽŶƚƌŽůůĞƌƵƐŝŶŐĂDϴ
8.
Connect F2 from OEM Controller to F2Žůƚ͕>ŽĐŬtĂƐŚĞƌĂŶĚ&ůĂƚ
&ϭΘ&Ϯ ϲŵŵŽůƚ ϲϬŝŶͲůďƐͬ ϱĨƚůďƐͬϲ͘ϴEŵ
;&Ϳ ŽŶŶĞĐƚƚŚĞDĂŝŶEĞŐĂƚŝǀĞůĂĐŬWŽǁĞƌ ĂďůĞ;ĂďůĞĨƌŽŵƚŚĞĂƚƚĞƌLJǁŝƚŚƚŚĞŽƌŝŐŝŶĂůZŝŶŐdĞƌŵŝŶĂůͿƚŽƚŚĞͲdĞƌŵŝŶĂůŽŶƚŚĞ
terminal using spade connector
ͲͬDͬн ϴŵŵŽůƚ ϭϱϬŝŶͲůďƐͬϭϮ͘ϱĨƚůďƐͬ ϭϲ͘ϵEŵ
ŽŶƚƌŽůůĞƌƵƐŝŶŐĂDϴŽůƚ͕> ŽĐŬtĂƐŚĞƌĂŶĚ&ůĂƚtĂƐŚĞƌ͘
;'Ϳ/ŶƐƚĂůůƚŚĞ&ϭ&ŝĞůĚtŝƌĞ
ĨƌŽŵƚŚĞŽƌŝŐŝŶĂůŽŶƚƌŽůůĞƌƚŽƚŚĞ&ϭdĞƌŵŝŶĂůŽŶƚŚĞŽŶƚƌŽůůĞƌƵƐŝŶŐĂ^ƉĂĚĞŽŶŶĞĐƚŽƌ͘
;ƵƐƵĂůůLJŐƌĞĞŶͿ
;,Ϳ /ŶƐƚĂůůƚŚĞ&Ϯ&ŝĞůĚtŝƌĞ;ƵƐƵĂůůLJďůĂĐŬͿ ĨƌŽŵƚŚĞŽƌŝŐŝŶĂůŽŶƚƌŽůůĞƌƚŽƚŚĞ&ϮdĞƌŵŝŶĂůŽŶ ƚŚĞ ŽŶƚƌŽůůĞƌdĞƌŵŝŶĂůƵƐŝŶŐĂ^ƉĂĚĞ
ŽŶŶĞĐƚŽƌ͘
15
ϭϳ
INSTALLATION/ SERVICE MANUAL
INSTALLATION INSTRUCTIONS
YAMAHA G19/22 Installation
(GE) Cont’d
;/Ϳ /ŶƐƚĂůůƚŚĞϮϬWŝŶŽŶŶĞĐƚŽƌŽŶƚ ŚĞsĞŚŝĐůĞDŽĚƵůĞ,ĂƌŶĞƐƐƚŽƚŚĞŽŶƚƌŽůůĞƌ͘
9.
Install the 20 Pin Connector on the Navitas
Vehicle Module Harness to TSX Controller
10. Install the 23 Pin OEM Connector to the
Navitas Vehicle 23 Pin Module Harness
11. Optional (install 8 pin connector for the
“On The Fly” Programmer).
;:Ϳ /ŶƐƚĂůůƚŚĞϮϲW/EŽŶŶĞĐƚŽƌĨƌŽŵƚ ŚĞs ĞŚŝĐůĞtŝƌŝŶŐ,ĂƌŶĞƐƐƚ Žƚ ŚĞϮϲWŝŶŽŶŶĞĐ
;<Ϳ dŚŝƐϴWŝŶŽŶŶĞĐƚŽƌŝƐĨŽƌƚŚĞŽƉƚŝŽŶĂů Kd&͞KŶdŚĞ&ůLJ͟WƌŽŐƌĂŵŵĞƌ͘
EKd͗d
ŝƉdŝĞƐƐ
ƚŚĞ ŽŶŶ
ŽŶŶĞĐƚŽƌWůƵŐ>ŽĐĂƚŝŽŶ
ŽŶƚƌŽůůĞƌ ,ĂƌŶĞƐƐ
ϭ ŽŶƚƌŽůůĞƌ
ϮϬWŝŶshould
NOTE:
The harness
be oriented
ŽŶŶĞĐƚŽƌ
and secured with Zip
EKdTies
h^ to prevent
Ϯ ZĞƐĞƌǀĞĚ
ϯWŝŶ
sĞŚŝĐůĞ
ϰ
water and debris from accumulating in
͞KŶdŚĞ&ůLJ͟ WƌŽŐƌĂŵŵĞƌ
the
connectors
ϯ Kd&
ϴWŝŶ
ϰ sĞŚŝĐůĞ
Ύ;KƉƚŝŽŶĂůͿ EŽƚŝŶĐůƵĚĞĚ
ϮϲWŝŶ sĞŚŝĐůĞ ,ĂƌŶĞƐƐ ŽŶŶĞĐƚŽƌ
EŽǁƚŚĞsĞŚŝĐůĞ͛ƐDĂŝŶĂƚƚĞƌLJWŽƐŝƚŝǀĞĂŶĚEĞŐĂƚŝǀĞĂďů
ϭϲ
Now the Vehicle’s Main Battery Positive and Negative Cables can be re-connected
16
INSTALLATION/ SERVICE MANUAL
/ E ^ d >> d/ K E ͬ ^ Zs / DEh>
INSTALLATION INSTRUCTIONS
/E^d>>d/KE
/E^dZhd/KE^
YAMAHA
G19/22
Installation (MORIC)
<DPDKD'ULYH
ZLWK0RULF-:,QVWDOODWLRQ
ͻ
ͻ
ĞĨŽƌĞƌĞŵŽǀŝŶŐƚŚĞŽƌŝŐŝŶĂůŽŶƚƌŽůůĞƌ ƚĂŬĞŶŽƚĞŽƌƚĂŬĞĂƉŚŽƚŽŽĨƚŚĞϱŽŶƚƌŽůůĞƌdĞƌŵŝŶĂůƐĂŶĚƚŚĞŝƌĐŽƌƌĞƐƉŽŶĚŝŶŐtŝƌĞƐ͘DĂŬĞƐƵƌĞ
ƚŚĂƚƚŚĞŐƌŽƵƉƐŽĨǁŝƌĞƐƐƚĂLJƚŽŐĞƚŚĞƌ͘
ZĞŵŽǀĞ;ͿƚŚĞKƌŝŐŝŶĂůsĞŚŝĐůĞŽŶƚƌŽůůĞƌ͘;Ϳ/ŶƐƚĂůůƚŚĞŽŶƚƌŽůůĞƌƵƐŝŶŐƚŚĞϯƐĐƌĞǁƐĨƌŽŵ ƚŚĞŽƌŝŐŝŶĂůĐŽŶƚƌŽůůĞƌ͘
hd/KE͗ KEKd KEEd Ez t/Z^ KZ >^ hEd/> &dZ ^dW ͘
>ŽĐĂƚĞ;ͿƚŚĞzĐĂďůĞŽŶƚŚĞsĞŚŝĐůĞ,ĂƌŶĞƐƐ͗ƐŚŽǁŶĂƐϮŝŶƚŚĞƉŚŽƚŽďĞůŽǁ͘dŚŝƐĐĂďůĞĐŽŶƐŝƐƚƐŽĨϮĐĂďůĞƐĐƌŝŵƉĞĚƚŽŐĞƚŚĞƌŝŶƚŽ
ĂZŝŶŐdĞƌŵŝŶĂů͘dŚĞŽŶĞƐŝĚĞĐŽŵĞƐĨƌŽŵƚŚĞĂƚƚĞƌLJEĞŐĂƚŝǀĞĂŶĚƚŚĞŽƚŚĞƌƐŝĚĞĐŽŵĞƐĨƌŽŵ ƚŚĞϮŽŶƚŚĞDŽƚŽƌ͘hƐĞĂƉĂŝƌŽĨƐŝĚĞ
ĐƵƚƚĞƌƐƚŽĐƵƚƚŚĞϮƐŝĚĞŽĨƚŚĞĐĂďůĞĂƚƚŚĞZŝŶŐdĞƌŵŝŶĂů͘dŚĞŶĐƌŝŵƉŽŶĂŶĞǁƌŝŶŐƚĞƌŵŝŶĂů ;ŝŶĐůƵĚĞĚŝŶƚŚĞ,ĂƌŶĞƐƐďĂŐͿ͘EKd͗
dŚĞZŝŶŐdĞƌŵŝŶĂůƐŽŶƚŚĞŽƌŝŐŝŶĂů,ĂƌŶĞƐƐŵĂLJŶĞĞĚƚŽďĞĚƌŝůůĞĚŽƵƚƚŽϱͬϭϲ͟ƚŽĂůůŽǁƚŚĞEĞǁ ,ĂƌŶĞƐƐƚŽďĞĐŽŶŶĞĐƚĞĚƚŽƚŚĞŶĞǁ
ŽŶƚƌŽůůĞƌ͘
dŽƌƋƵĞ^ƉĞĐŝĨŝĐĂƚŝŽŶƐ
Note: OEM Cable bolts in Fig A. can be used to to mount the
TSX controller to the cart in step B.
&ϭΘ&Ϯ ϲŵŵŽůƚ ϲϬŝŶͲůďƐͬ ϱĨƚůďƐͬϲ͘ϴEŵ
ͲͬDͬн ϴŵŵŽůƚ ϭϱϬ ŝŶͲůďƐͬ ϭϮ͘ϱĨƚůďƐͬ ϭϲ͘ϵEŵ
^ W,KdKKE&K>>Kt/E' W'
;ͿŽŶŶĞĐƚƚŚĞDŽƚŽƌĂďůĞ;ƵƐƵĂůůLJǁŚŝƚĞͿĨƌŽŵƚŚĞŽƌŝŐŝŶĂůŽŶƚƌŽůůĞƌƚ Žƚ ŚĞDdĞƌŵŝŶĂůƐŽŶƚŚĞŽŶƚƌŽůůĞƌƵƐŝŶŐĂDϴŽůƚ͕>ŽĐŬ
tĂƐŚĞƌĂŶĚ&ůĂƚ tĂƐŚĞƌ͘
;Ϳ ŽŶŶĞĐƚƚŚĞDĂŝŶWŽƐŝƚŝǀĞZĞĚWŽǁĞƌ ĂďůĞĨƌŽŵƚ ŚĞsĞŚŝĐůĞ^ŽůĞŶŽŝĚĂŶĚƚŚĞůĂĐŬϮĂďůĞ;ĂďůĞƚ ŚĂƚǁ ĂƐĐƵƚĂŶĚŚĂƐƚŚĞEĞǁZŝŶŐ
dĞƌŵŝŶĂůͿƚŽƚŚĞнdĞƌŵŝŶĂůƐŽŶƚŚĞŽŶƚƌŽůůĞƌƵƐŝŶŐĂDϴŽůƚ͕>ŽĐŬtĂƐŚĞƌĂŶĚ&ůĂƚtĂƐŚĞƌ͘
;&Ϳ ŽŶŶĞĐƚƚŚĞDĂŝŶEĞŐĂƚŝǀĞůĂĐŬWŽǁĞƌ ĂďůĞ;ĂďůĞĨƌŽŵƚŚĞĂƚƚĞƌLJǁŝƚŚƚŚĞŽƌŝŐŝŶĂůZŝŶŐdĞƌŵŝŶĂůͿƚŽƚŚĞͲdĞƌŵŝŶĂůŽŶƚŚĞ
ŽŶƚƌŽůůĞƌƵƐŝŶŐĂDϴŽůƚ͕> ŽĐŬtĂƐŚĞƌĂŶĚ&ůĂƚtĂƐŚĞƌ͘
;'Ϳ/ŶƐƚĂůůƚŚĞ&ϭ&ŝĞůĚtŝƌĞ;ƵƐƵĂůůLJŐƌĞĞŶͿĨƌŽŵƚŚĞŽƌŝŐŝŶĂůŽŶƚƌŽůůĞƌƚŽƚŚĞ&ϭdĞƌŵŝŶĂůŽŶƚŚĞŽŶƚƌŽůůĞƌƵƐŝŶŐĂ^ƉĂĚĞŽŶŶĞĐƚŽƌ͘
;,Ϳ /ŶƐƚĂůůƚŚĞ&Ϯ&ŝĞůĚtŝƌĞ;ƵƐƵĂůůLJďůĂĐŬͿ ĨƌŽŵƚŚĞŽƌŝŐŝŶĂůŽŶƚƌŽůůĞƌƚŽƚŚĞ&ϮdĞƌŵŝŶĂůŽŶ ƚŚĞ ŽŶƚƌŽůůĞƌdĞƌŵŝŶĂůƵƐŝŶŐĂ^ƉĂĚĞ
ŽŶŶĞĐƚŽƌ͘
ϭϳ
17
/ EINSTALLATION/
^ d >> d/ K E ͬSERVICE
^ Zs / DEh>
MANUAL
Ͳ
D
н
&ϭ
<DPDKD'ULYH ZLWK0RULF-:,QVWDOODWLRQFRQW¶G
YAMAHA
G19/22 Installation (MORIC) Cont’d
&Ϯ
/E^d>>d/KE
/E^dZhd/KE^
INSTALLATION INSTRUCTIONS
;/Ϳ /ŶƐƚĂůůƚŚĞϮϬWŝŶŽŶŶĞĐƚŽƌŽŶƚ ŚĞsĞŚŝĐůĞDŽĚƵůĞ,ĂƌŶĞƐƐƚŽƚŚĞŽŶƚƌŽůůĞƌ͘
;:Ϳ /ŶƐƚĂůůƚŚĞϮϲW/EŽŶŶĞĐƚŽƌĨƌŽŵƚ ŚĞs ĞŚŝĐůĞtŝƌŝŶŐ,ĂƌŶĞƐƐƚ Žƚ ŚĞϮϲWŝŶŽŶŶĞĐƚŽƌŽŶƚ ŚĞE s/d^s ĞŚŝĐůĞDŽĚƵůĞ,ĂƌŶĞƐƐ͘
;<Ϳ dŚŝƐϴWŝŶŽŶŶĞĐƚŽƌŝƐĨŽƌƚŚĞŽƉƚŝŽŶĂů Kd&͞KŶdŚĞ&ůLJ͟WƌŽŐƌĂŵŵĞƌ͘
EKd͗dŚĞ,ĂƌŶĞƐƐƐŚŽƵůĚďĞŽƌŝĞŶƚĞĚĂŶĚƐĞĐƵƌĞĚǁŝƚŚ
ŝƉdŝĞƐƐŽƚŚĂƚǁĂƚĞƌĂŶĚĚĞďƌŝƐĚŽĞƐŶŽƚĂĐĐƵŵƵůĂƚĞŝŶ
ƚŚĞ ŽŶŶĞĐƚŽƌƐ͘
ŽŶŶĞĐƚŽƌWůƵŐ>ŽĐĂƚŝŽŶ
ϭ ŽŶƚƌŽůůĞƌ ϮϬWŝŶ ŽŶƚƌŽůůĞƌ ,ĂƌŶĞƐƐ
ŽŶŶĞĐƚŽƌ
EKd h^
Ϯ ZĞƐĞƌǀĞĚ
ϯWŝŶ
ϯ Kd&
ϰ sĞŚŝĐůĞ
sĞŚŝĐůĞDŽĚƵůĞ,ĂƌŶĞƐƐ;zĂŵĂŚĂ Z͘Ϳ
ϰ
͞KŶdŚĞ&ůLJ͟ WƌŽŐƌĂŵŵĞƌ
ϴWŝŶ
Ύ;KƉƚŝŽŶĂůͿ EŽƚŝŶĐůƵĚĞĚ
ϮϲWŝŶ sĞŚŝĐůĞ ,ĂƌŶĞƐƐ ŽŶŶĞĐƚŽƌ
Ϯ
ϭ
ϯ
EŽǁƚŚĞsĞŚŝĐůĞ͛ƐDĂŝŶĂƚƚĞƌLJWŽƐŝƚŝǀĞĂŶĚEĞŐĂƚŝǀĞĂďůĞƐĐĂŶďĞƌĞͲĐŽŶŶĞĐƚĞĚ͘
ϭϲ
18
/ E ^ d >> d/ KE ͬ ^ Zs / DEh>
/E^d>>d/KE /E^dZhd/KE^
<DPDKD'ULYH ZLWK0RULF-:,QVWDOODWLRQ
ͻ
ͻ
ĞĨŽƌĞƌĞŵŽǀŝŶŐƚŚĞŽƌŝŐŝŶĂůŽŶƚƌŽůůĞƌ ƚĂŬĞŶŽƚĞŽƌƚĂŬĞĂƉŚŽƚŽŽĨƚŚĞϱŽŶƚƌŽůůĞƌdĞƌŵŝŶĂůƐĂŶĚƚŚĞŝƌĐŽƌƌĞƐƉŽŶĚŝŶŐtŝƌĞƐ͘DĂŬĞƐƵƌĞ
ƚŚĂƚƚŚĞŐƌŽƵƉƐŽĨǁŝƌĞƐƐƚĂLJƚŽŐĞƚŚĞƌ͘
ZĞŵŽǀĞ;ͿƚŚĞKƌŝŐŝŶĂůsĞŚŝĐůĞŽŶƚƌŽůůĞƌ͘;Ϳ/ŶƐƚĂůůƚŚĞŽŶƚƌŽůůĞƌƵƐŝŶŐƚŚĞϯƐĐƌĞǁƐĨƌŽŵ ƚŚĞŽƌŝŐŝŶĂůĐŽŶƚƌŽůůĞƌ͘
hd/KE͗ KEKd KEEd Ez t/Z^ KZ >^ hEd/> &dZ ^dW ͘
>ŽĐĂƚĞ;ͿƚŚĞzĐĂďůĞŽŶƚŚĞsĞŚŝĐůĞ,ĂƌŶĞƐƐ͗ƐŚŽǁŶĂƐϮŝŶƚŚĞƉŚŽƚŽďĞůŽǁ͘dŚŝƐĐĂďůĞĐŽŶƐŝƐƚƐŽĨϮĐĂďůĞƐĐƌŝŵƉĞĚƚŽŐĞƚŚĞƌŝŶƚŽ
ĂZŝŶŐdĞƌŵŝŶĂů͘dŚĞŽŶĞƐŝĚĞĐŽŵĞƐĨƌŽŵƚŚĞĂƚƚĞƌLJEĞŐĂƚŝǀĞĂŶĚƚŚĞŽƚŚĞƌƐŝĚĞĐŽŵĞƐĨƌŽŵ ƚŚĞϮŽŶƚŚĞDŽƚŽƌ͘hƐĞĂƉĂŝƌŽĨƐŝĚĞ
ĐƵƚƚĞƌƐƚŽĐƵƚƚŚĞϮƐŝĚĞŽĨƚŚĞĐĂďůĞĂƚƚŚĞZŝŶŐdĞƌŵŝŶĂů͘dŚĞŶĐƌŝŵƉŽŶĂŶĞǁƌŝŶŐƚĞƌŵŝŶĂů ;ŝŶĐůƵĚĞĚŝŶƚŚĞ,ĂƌŶĞƐƐďĂŐͿ͘EKd͗
dŚĞZŝŶŐdĞƌŵŝŶĂůƐŽŶƚŚĞŽƌŝŐŝŶĂů,ĂƌŶĞƐƐŵĂLJŶĞĞĚƚŽďĞĚƌŝůůĞĚŽƵƚƚŽϱͬϭϲ͟ƚŽĂůůŽǁƚŚĞEĞǁ ,ĂƌŶĞƐƐƚŽďĞĐŽŶŶĞĐƚĞĚƚŽƚŚĞŶĞǁ
ŽŶƚƌŽůůĞƌ͘
dŽƌƋƵĞ^ƉĞĐŝĨŝĐĂƚŝŽŶƐ
&ϭΘ&Ϯ ϲŵŵŽůƚ ϲϬŝŶͲůďƐͬ ϱĨƚůďƐͬϲ͘ϴEŵ
ͲͬDͬн ϴŵŵŽůƚ ϭϱϬŝŶͲůďƐͬϭϮ͘ϱĨƚůďƐͬ ϭϲ͘ϵEŵ
^ W,KdKKE&K>>Kt/E' W'
;ͿŽŶŶĞĐƚƚŚĞDŽƚŽƌĂďůĞ;ƵƐƵĂůůLJǁŚŝƚĞͿĨƌŽŵƚŚĞŽƌŝŐŝŶĂůŽŶƚƌŽůůĞƌƚ Žƚ ŚĞDdĞƌŵŝŶĂůƐŽŶƚŚĞŽŶƚƌŽůůĞƌƵƐŝŶŐĂDϴŽůƚ͕>ŽĐŬ
tĂƐŚĞƌĂŶĚ&ůĂƚtĂƐŚĞƌ͘
;Ϳ ŽŶŶĞĐƚƚŚĞDĂŝŶWŽƐŝƚŝǀĞZĞĚWŽǁĞƌ ĂďůĞĨƌŽŵƚ ŚĞsĞŚŝĐůĞ^ŽůĞŶŽŝĚĂŶĚƚŚĞůĂĐŬϮĂďůĞ;ĂďůĞƚ ŚĂƚǁ ĂƐĐƵƚĂŶĚŚĂƐƚŚĞEĞǁZŝŶŐ
dĞƌŵŝŶĂůͿƚŽƚŚĞнdĞƌŵŝŶĂůƐŽŶƚŚĞŽŶƚƌŽůůĞƌƵƐŝŶŐĂDϴŽůƚ͕>ŽĐŬtĂƐŚĞƌĂŶĚ&ůĂƚtĂƐŚĞƌ͘
;&Ϳ ŽŶŶĞĐƚƚŚĞDĂŝŶEĞŐĂƚŝǀĞůĂĐŬWŽǁĞƌ ĂďůĞ;ĂďůĞĨƌŽŵƚŚĞĂƚƚĞƌLJǁŝƚŚƚŚĞŽƌŝŐŝŶĂůZŝŶŐdĞƌŵŝŶĂůͿƚŽƚŚĞͲdĞƌŵŝŶĂůŽŶƚŚĞ
ŽŶƚƌŽůůĞƌƵƐŝŶŐĂDϴŽůƚ͕> ŽĐŬtĂƐŚĞƌĂŶĚ&ůĂƚtĂƐŚĞƌ͘
;'Ϳ/ŶƐƚĂůůƚŚĞ&ϭ&ŝĞůĚtŝƌĞ;ƵƐƵĂůůLJŐƌĞĞŶͿĨƌŽŵƚŚĞŽƌŝŐŝŶĂůŽŶƚƌŽůůĞƌƚŽƚŚĞ&ϭdĞƌŵŝŶĂůŽŶƚŚĞŽŶƚƌŽůůĞƌƵƐŝŶŐĂ^ƉĂĚĞŽŶŶĞĐƚŽƌ͘
;,Ϳ /ŶƐƚĂůůƚŚĞ&Ϯ&ŝĞůĚtŝƌĞ;ƵƐƵĂůůLJďůĂĐŬͿ ĨƌŽŵƚŚĞŽƌŝŐŝŶĂůŽŶƚƌŽůůĞƌƚŽƚŚĞ&ϮdĞƌŵŝŶĂůŽŶ ƚŚĞŽŶƚƌŽůůĞƌdĞƌŵŝŶĂůƵƐŝŶŐĂ^ƉĂĚĞ
ŽŶŶĞĐƚŽƌ͘
ϭϳ
19
/ E ^ d >> d/ K E ͬ ^ Zs / DEh>
Ͳ
D
н
&ϭ
<DPDKD'ULYH ZLWK0RULF-:,QVWDOODWLRQFRQW¶G
&Ϯ
/E^d>>d/KE /E^dZhd/KE^
;/Ϳ /ŶƐƚĂůůƚŚĞϮϬWŝŶŽŶŶĞĐƚŽƌŽŶƚ ŚĞsĞŚŝĐůĞDŽĚƵůĞ,ĂƌŶĞƐƐƚŽƚŚĞŽŶƚƌŽůůĞƌ͘
;:Ϳ /ŶƐƚĂůůƚŚĞϮϲW/EŽŶŶĞĐƚŽƌĨƌŽŵƚ ŚĞs ĞŚŝĐůĞtŝƌŝŶŐ,ĂƌŶĞƐƐƚ Žƚ ŚĞϮϲWŝŶŽŶŶĞĐƚŽƌŽŶƚ ŚĞE s/d^s ĞŚŝĐůĞDŽĚƵůĞ,ĂƌŶĞƐƐ͘
;<Ϳ dŚŝƐϴWŝŶŽŶŶĞĐƚŽƌŝƐĨŽƌƚŚĞŽƉƚŝŽŶĂů Kd&͞KŶdŚĞ&ůLJ͟WƌŽŐƌĂŵŵĞƌ͘
EKd͗dŚĞ,ĂƌŶĞƐƐƐŚŽƵůĚďĞŽƌŝĞŶƚĞĚĂŶĚƐĞĐƵƌĞĚǁŝƚŚ
ŝƉdŝĞƐƐŽƚŚĂƚǁĂƚĞƌĂŶĚĚĞďƌŝƐĚŽĞƐŶŽƚĂĐĐƵŵƵůĂƚĞŝŶ
ƚŚĞ ŽŶŶĞĐƚŽƌƐ͘
ŽŶŶĞĐƚŽƌWůƵŐ>ŽĐĂƚŝŽŶ
ŽŶƚƌŽůůĞƌ ,ĂƌŶĞƐƐ
ϭ ŽŶƚƌŽůůĞƌ ϮϬWŝŶ
ŽŶŶĞĐƚŽƌ
EKd h^
Ϯ ZĞƐĞƌǀĞĚ
ϯWŝŶ
ϯ Kd&
ϰ sĞŚŝĐůĞ
sĞŚŝĐůĞDŽĚƵůĞ,ĂƌŶĞƐƐ;zĂŵĂŚĂ Z͘Ϳ
ϰ
͞KŶdŚĞ&ůLJ͟ WƌŽŐƌĂŵŵĞƌ
Ύ;KƉƚŝŽŶĂůͿ EŽƚŝŶĐůƵĚĞĚ
ϮϲWŝŶ sĞŚŝĐůĞ ,ĂƌŶĞƐƐ ŽŶŶĞĐƚŽƌ
ϴWŝŶ
Ϯ
ϭ
ϯ
EŽǁƚŚĞsĞŚŝĐůĞ͛ƐDĂŝŶĂƚƚĞƌLJWŽƐŝƚŝǀĞĂŶĚEĞŐĂƚŝǀĞĂďůĞƐĐĂŶďĞƌĞͲĐŽŶŶĞĐƚĞĚ͘
ϭϲ
20
MANUAL
/ EINSTALLATION/
^ d >> d/ K E ͬSERVICE
^ Zs / DEh>
INSTALLATION INSTRUCTIONS
/E^d>>d/KE
/E^dZhd/KE^
CPC/CVG (SEVCON)
Installation
<DPDKD'ULYH
ZLWK0RULF-:,QVWDOODWLRQ
ͻ
ͻ
ĞĨŽƌĞƌĞŵŽǀŝŶŐƚŚĞŽƌŝŐŝŶĂůŽŶƚƌŽůůĞƌ ƚĂŬĞŶŽƚĞŽƌƚĂŬĞĂƉŚŽƚŽŽĨƚŚĞϱŽŶƚƌŽůůĞƌdĞƌŵŝŶĂůƐĂŶĚƚŚĞŝƌĐŽƌƌĞƐƉŽŶĚŝŶŐtŝƌĞƐ͘DĂŬĞƐƵƌĞ
ƚŚĂƚƚŚĞŐƌŽƵƉƐŽĨǁŝƌĞƐƐƚĂLJƚŽŐĞƚŚĞƌ͘
ZĞŵŽǀĞ;ͿƚŚĞKƌŝŐŝŶĂůsĞŚŝĐůĞŽŶƚƌŽůůĞƌ͘;Ϳ/ŶƐƚĂůůƚŚĞŽŶƚƌŽůůĞƌƵƐŝŶŐƚŚĞϯƐĐƌĞǁƐĨƌŽŵ ƚŚĞŽƌŝŐŝŶĂůĐŽŶƚƌŽůůĞƌ͘
hd/KE͗ KEKd KEEd Ez t/Z^ KZ >^ hEd/> &dZ ^dW ͘
Wire
Connections
1. (F2) wire from F1/S1 on motor
F2
2. (B-) wire from battery main negative (-)
3. (M) wire from A2 on motor
B-
4. (B+) wire from solenoid - main positive (+), & wire
from A1 on motor
M
5. (F1) WIRE FROM F2/S2 ON MOTOR
B+
> d/ K E ͬ ^ Zs / DEh>
6.
If
it
goes
backwards,
reverse
the
F1
&
F2
>ŽĐĂƚĞ;ͿƚŚĞzĐĂďůĞŽŶƚŚĞsĞŚŝĐůĞ,ĂƌŶĞƐƐ͗ƐŚŽǁŶĂƐϮŝŶƚŚĞƉŚŽƚŽďĞůŽǁ͘dŚŝƐĐĂďůĞĐŽŶƐŝƐƚƐŽĨϮĐĂďůĞƐĐƌŝŵƉĞĚƚŽŐĞƚŚĞƌŝŶƚŽ
/KEĂZŝŶŐdĞƌŵŝŶĂů͘dŚĞŽŶĞƐŝĚĞĐŽŵĞƐĨƌŽŵƚŚĞĂƚƚĞƌLJEĞŐĂƚŝǀĞĂŶĚƚŚĞŽƚŚĞƌƐŝĚĞĐŽŵĞƐĨƌŽŵ
/E^dZhd/KE^
ƚŚĞϮŽŶƚŚĞDŽƚŽƌ͘hƐĞĂƉĂŝƌŽĨƐŝĚĞ
ĐƵƚƚĞƌƐƚŽĐƵƚƚŚĞϮƐŝĚĞŽĨƚŚĞĐĂďůĞĂƚƚŚĞZŝŶŐdĞƌŵŝŶĂů͘dŚĞŶĐƌŝŵƉŽŶĂŶĞǁƌŝŶŐƚĞƌŵŝŶĂů ;ŝŶĐůƵĚĞĚŝŶƚŚĞ,ĂƌŶĞƐƐďĂŐͿ͘EKd͗
F1
ZLWK0RULF-:,QVWDOODWLRQ
ŶĞǁ
dŚĞZŝŶŐdĞƌŵŝŶĂůƐŽŶƚŚĞŽƌŝŐŝŶĂů,ĂƌŶĞƐƐŵĂLJŶĞĞĚƚŽďĞĚƌŝůůĞĚŽƵƚƚŽϱͬϭϲ͟ƚŽĂůůŽǁƚŚĞEĞǁ ,ĂƌŶĞƐƐƚŽďĞĐŽŶŶĞĐƚĞĚƚŽƚŚĞ
ŽŶƚƌŽůůĞƌ͘
dŽƌƋƵĞ^ƉĞĐŝĨŝĐĂƚŝŽŶƐ
&ϭΘ&Ϯ ϲŵŵŽůƚ ϲϬŝŶͲůďƐͬ ϱĨƚůďƐͬϲ͘ϴEŵ
fig. 1
ͲͬDͬн ϴŵŵŽůƚ ϭϱϬŝŶͲůďƐͬϭϮ͘ϱĨƚůďƐͬ ϭϲ͘ϵEŵ
ŬĞĂƉŚŽƚŽŽĨƚŚĞϱŽŶƚƌŽůůĞƌdĞƌŵŝŶĂůƐĂŶĚƚŚĞŝƌĐŽƌƌĞƐƉŽŶĚŝŶŐtŝƌĞƐ͘DĂŬĞƐƵƌĞ
ŚĞŽŶƚƌŽůůĞƌƵƐŝŶŐƚŚĞϯƐĐƌĞǁƐĨƌŽŵ
ƚŚĞŽƌŝŐŝŶĂůĐŽŶƚƌŽůůĞƌ͘
^ KZ >^ hEd/> &dZ ^dW ͘Overhead view showing
Module Harness in place
^ W,KdKKE&K>>Kt/E' W'
;ͿŽŶŶĞĐƚƚŚĞDŽƚŽƌĂďůĞ;ƵƐƵĂůůLJǁŚŝƚĞͿĨƌŽŵƚŚĞŽƌŝŐŝŶĂůŽŶƚƌŽůůĞƌƚ Žƚ ŚĞDdĞƌŵŝŶĂůƐŽŶƚŚĞŽŶƚƌŽůůĞƌƵƐŝŶŐĂDϴŽůƚ͕>ŽĐŬ
ƐϮŝŶƚŚĞƉŚŽƚŽďĞůŽǁ͘dŚŝƐĐĂďůĞĐŽŶƐŝƐƚƐŽĨϮĐĂďůĞƐĐƌŝŵƉĞĚƚŽŐĞƚŚĞƌŝŶƚŽ
tĂƐŚĞƌĂŶĚ&ůĂƚtĂƐŚĞƌ͘
EĞŐĂƚŝǀĞĂŶĚƚŚĞŽƚŚĞƌƐŝĚĞĐŽŵĞƐĨƌŽŵ
ƚŚĞϮŽŶƚŚĞDŽƚŽƌ͘hƐĞĂƉĂŝƌŽĨƐŝĚĞ
;Ϳ ŽŶŶĞĐƚƚŚĞDĂŝŶWŽƐŝƚŝǀĞZĞĚWŽǁĞƌ
ĂďůĞĨƌŽŵƚ ŚĞsĞŚŝĐůĞ^ŽůĞŶŽŝĚĂŶĚƚŚĞůĂĐŬϮĂďůĞ;ĂďůĞƚ ŚĂƚǁ ĂƐĐƵƚĂŶĚŚĂƐƚŚĞEĞǁZŝŶŐ
ŶĂů͘dŚĞŶĐƌŝŵƉŽŶĂŶĞǁƌŝŶŐƚĞƌŵŝŶĂů ;ŝŶĐůƵĚĞĚŝŶƚŚĞ,ĂƌŶĞƐƐďĂŐͿ͘EKd͗
dĞƌŵŝŶĂůͿƚŽƚŚĞнdĞƌŵŝŶĂůƐŽŶƚŚĞŽŶƚƌŽůůĞƌƵƐŝŶŐĂDϴ
,ĂƌŶĞƐƐƚŽďĞĐŽŶŶĞĐƚĞĚƚŽƚŚĞŶĞǁ Žůƚ͕>ŽĐŬtĂƐŚĞƌĂŶĚ&ůĂƚtĂƐŚĞƌ͘
ŽďĞĚƌŝůůĞĚŽƵƚƚŽϱͬϭϲ͟ƚŽĂůůŽǁƚŚĞEĞǁ
;&Ϳ ŽŶŶĞĐƚƚŚĞDĂŝŶEĞŐĂƚŝǀĞůĂĐŬWŽǁĞƌ
ĂďůĞ;ĂďůĞĨƌŽŵƚŚĞĂƚƚĞƌLJǁŝƚŚƚŚĞŽƌŝŐŝŶĂůZŝŶŐdĞƌŵŝŶĂůͿƚŽƚŚĞͲdĞƌŵŝŶĂůŽŶƚŚĞ
dŽƌƋƵĞ^ƉĞĐŝĨŝĐĂƚŝŽŶƐ
ŽŶƚƌŽůůĞƌƵƐŝŶŐ
ĂDϴŽůƚ͕> ŽĐŬtĂƐŚĞƌĂŶĚ&ůĂƚtĂƐŚĞƌ͘
&ϭΘ&Ϯ ϲŵŵŽůƚ ϲϬŝŶͲůďƐͬ ϱĨƚůďƐͬϲ͘ϴEŵ
;'Ϳ/ŶƐƚĂůůƚŚĞ&ϭ&ŝĞůĚtŝƌĞ;ƵƐƵĂůůLJŐƌĞĞŶͿĨƌŽŵƚŚĞŽƌŝŐŝŶĂůŽŶƚƌŽůůĞƌƚŽƚŚĞ&ϭdĞƌŵŝŶĂůŽŶƚŚĞŽŶƚƌŽůůĞƌƵƐŝŶŐĂ^ƉĂĚĞŽŶŶĞĐƚŽƌ͘
ͲͬDͬн ϴŵŵŽůƚ ϭϱϬŝŶͲůďƐͬϭϮ͘ϱĨƚůďƐͬ ϭϲ͘ϵEŵ
;,Ϳ /ŶƐƚĂůůƚŚĞ&Ϯ&ŝĞůĚtŝƌĞ;ƵƐƵĂůůLJďůĂĐŬͿ ĨƌŽŵƚŚĞŽƌŝŐŝŶĂůŽŶƚƌŽůůĞƌƚŽƚŚĞ&ϮdĞƌŵŝŶĂůŽŶ ƚŚĞ ŽŶƚƌŽůůĞƌdĞƌŵŝŶĂůƵƐŝŶŐĂ^ƉĂĚĞfig. 2
ŽŶŶĞĐƚŽƌ͘
ϭϳ
21
INSTALLATION/ SERVICE MANUAL
INSTALLATION INSTRUCTIONS
CPC/CVG (SEVCON) Installation Cont’d
7.
Install the 20 Pin Connector (fig 3 & 4, A) on
the Navitas Vehicle Module Harness to TSX
Controller
8.
Install the 16 Pin OEM Connector (fig 3 & 4,
B) to the Navitas Vehicle 23 Pin Module
Harness
9.
Optional - connect 8 pin connector (fig 3 & 4
C) to the “On The Fly” Programmer).
A
B
C
fig. 3
NOTE: The harness should be oriented and secured with Zip Ties to prevent
water and debris from accumulating in the connectors
Vehicle Module Harness
C
A
A.
20 Pin Connector
B.
16 Pin OEM Connector
C.
8 pin connector
B
fig. 4
The Vehicle’s Main Battery Positive and Negative Cables can now be re-connected.
22
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,ĂƌŶĞƐƐ
PART #10-000686
OTF 1.0 Programmer
(3.75 m Cable)
,ĂƌŶĞƐƐ
,ĂƌŶĞƐƐ
WZdηϭϬͲϬϬϬϲϴϲ
Kd&ϭ͘ϬWƌŽŐƌĂŵŵĞƌ
;ϯ͘ϳϱŵĐĂďůĞͿ
WZd ηϭϬͲϬϬϬϲϰϰ
Kd&ϭ͘ϬWƌŽŐƌĂŵŵĞƌ
;Ϯ͘ϳŵĐĂďůĞͿ OTF 1.0 Cable WZdηϭϬͲϬϬϬϲϴϲ
connects to the 8 Pin
Kd&ϭ͘ϬWƌŽŐƌĂŵŵĞƌ
WZd ηϭϬͲϬϬϬϲϰϰ
Connector on the ;ϯ͘ϳϱŵĐĂďůĞͿ
Controller harness
Kd&ϭ͘ϬWƌŽŐƌĂŵŵĞƌ
;Ϯ͘ϳŵĐĂďůĞͿ
dŽŝŶƐƚĂůůdŚĞKd&͞KŶƚŚĞ&ůLJ͟WƌŽŐƌĂŵŵĞƌ
ͻ &ŝƌƐƚŵĂŬĞƐƵƌĞƚŚĞsĞŚŝĐůĞZhEͬdKt^ǁŝƚĐŚŝƐŝŶƚŚĞdKtƉŽƐŝƚŝŽŶĂŶĚƚŚĞ<ĞLJŝƐƚƵƌŶĞĚŽĨĨ͘
WZdηϭϬͲϬϬϬϲϴϲ
dŽŝŶƐƚĂůůdŚĞKd&͞KŶƚŚĞ&ůLJ͟WƌŽŐƌĂŵŵĞƌ
ͻ dŚĞKd&ĐĂŶďĞŵŽƵŶƚĞĚŽŶ
ƚ ŚĞsĞŚŝĐůĞŽƌƌĞŵŽǀĞĚĂŶĚƵƐĞĚĂƐƌĞƋƵŝƌĞĚ
ĨŽƌƉƌŽŐƌĂŵŵŝŶŐƉƵƌƉŽƐĞƐ͘
Kd&ϭ͘ϬWƌŽŐƌĂŵŵĞƌ
WZd
ηϭϬͲϬϬϬϲϰϰ
ͻ &ŝƌƐƚŵĂŬĞƐƵƌĞƚŚĞsĞŚŝĐůĞZhEͬdKt^ǁŝƚĐŚŝƐŝŶƚŚĞdKtƉŽƐŝƚŝŽŶĂŶĚƚŚĞ<ĞLJŝƐƚƵƌŶĞĚŽĨĨ͘
ͻ dŚĞKd&ĐĂŶďĞŵŽƵŶƚĞĚŽŶƚ ŚĞsĞŚŝĐůĞŽƌƌĞŵŽǀĞĚĂŶĚƵƐĞĚĂƐƌĞƋƵŝƌĞĚ
ĨŽƌƉƌŽŐƌĂŵŵŝŶŐƉƵƌƉŽƐĞƐ͘
ͻ dŚĞKd&ŚĂƐĂůŽŶŐĞŶŽƵŐŚĂďůĞƚŽĂůůŽǁŝƚƚŽďĞŵŽƵŶƚĞĚƚŽƚŚĞĂƐŚĂƌĞĂ͘DĂŬĞƐƵƌĞƚŽƌƵŶƚŚĞĂďůĞŝŶĂŶĂƌĞĂǁŚĞƌĞŝƚĐĂŶŶŽƚ
;ϯ͘ϳϱŵĐĂďůĞͿ
Kd&ϭ͘ϬWƌŽŐƌĂŵŵĞƌ
ͻ dŚĞKd&ŚĂƐĂůŽŶŐĞŶŽƵŐŚĂďůĞƚŽĂůůŽǁŝƚƚŽďĞŵŽƵŶƚĞĚƚŽƚŚĞĂƐŚĂƌĞĂ͘DĂŬĞƐƵƌĞƚŽƌƵŶƚŚĞĂďůĞŝŶĂŶĂƌĞĂǁŚĞƌĞŝƚĐĂŶŶŽƚ
ŐĞƚƉŝŶĐŚĞĚ͕ĚĂŵĂŐĞĚŽƌǁĞƚ͘ŝ͘Ğ͘hŶĚĞƌƚŚĞ&ůŽŽƌ
DĂƚŝŶƚŚĞǁŝƌŝŶŐĐŚĂŶŶĞů͘hƐĞƚŚĞsĞůĐƌŽ
ƉƌŽǀŝĚĞĚƚŽƐĞĐƵƌĞŝƚƚŽĂŶŽƉĞŶĂƌĞĂŽŶ
;Ϯ͘ϳŵĐĂďůĞͿ ƉƌŽǀŝĚĞĚƚŽƐĞĐƵƌĞŝƚƚŽĂŶŽƉĞŶĂƌĞĂŽŶ
ŐĞƚƉŝŶĐŚĞĚ͕ĚĂŵĂŐĞĚŽƌǁĞƚ͘ŝ͘Ğ͘hŶĚĞƌƚŚĞ&ůŽŽƌDĂƚŝŶƚŚĞǁŝƌŝŶŐĐŚĂŶŶĞů͘hƐĞƚŚĞsĞůĐƌŽ
ƚŚĞ ĂƐŚ͘
ƚŚĞĂƐŚ͘
ƚ ŚĞKWd&ŝŶ
ƚ Žƚ ŚĞϴWŝŶĐŽŶŶĞĐƚŽƌŽŶ
ŚĞ,ĂƌŶĞƐƐ͘
ͻ WůƵŐƚŚĞĞ ŶĚŽĨƚͻŚĞWůƵŐƚŚĞ
Kd&ŝŶĞƚŶĚŽĨ
Žƚ ŚĞϴ
ŝŶĐŽŶŶĞĐƚŽƌŽŶ
ƚ ŚĞ,ƚĂƌŶĞƐƐ͘
dŽŝŶƐƚĂůůdŚĞKd&͞KŶƚŚĞ&ůLJ͟WƌŽŐƌĂŵŵĞƌ
ͻ &ŝƌƐƚŵĂŬĞƐƵƌĞƚŚĞsĞŚŝĐůĞZhEͬdKt^ǁŝƚĐŚŝƐŝŶƚŚĞdKtƉŽƐŝƚŝŽŶĂŶĚƚŚĞ<ĞLJŝƐƚƵƌŶĞĚŽĨĨ͘
ͻ dŚĞKd&ĐĂŶďĞŵŽƵŶƚĞĚŽŶ
ƚ ŚĞsĞŚŝĐůĞŽƌƌĞŵŽǀĞĚĂŶĚƵƐĞĚ
ĂƐƌĞƋƵŝƌĞĚĨŽƌƉƌŽŐƌĂŵŵŝŶŐƉƵƌƉŽƐĞƐ͘
dŽƉƌŽŐƌĂŵƚŚĞĚĞƐŝƌĞĚƐĞƚƚŝŶŐƐŝŶƚŽƚŚĞĐŽŶƚƌŽůůĞƌ͗
ͻ
dŚĞKd&ŚĂƐĂůŽŶŐĞŶŽƵŐŚĂďůĞƚŽĂůůŽǁŝƚƚŽďĞŵŽƵŶƚĞĚƚŽƚŚĞĂƐŚĂƌĞĂ͘DĂŬĞƐƵƌĞƚŽƌƵŶƚŚĞĂďůĞŝŶĂŶĂƌĞĂǁŚĞƌĞŝƚĐĂŶŶŽƚ
ͻ dƵƌŶƚŚĞ>ŽĐŬKƵƚ<ĞLJĨƌŽŵƚŚĞ
>ŽĐŬƉŽƐŝƚŝŽŶƚŽƚŚĞ
hŶůŽĐŬ ƉŽƐŝƚŝŽŶ͘
dŽƉƌŽŐƌĂŵƚŚĞĚĞƐŝƌĞĚƐĞƚƚŝŶŐƐŝŶƚŽƚŚĞĐŽŶƚƌŽůůĞƌ͗
ŐĞƚƉŝŶĐŚĞĚ͕ĚĂŵĂŐĞĚŽƌǁĞƚ͘ŝ͘Ğ͘hŶĚĞƌƚŚĞ&ůŽŽƌ
DĂƚŝŶƚŚĞǁŝƌŝŶŐĐŚĂŶŶĞů͘hƐĞƚŚĞsĞůĐƌŽ
ƉƌŽǀŝĚĞĚƚŽƐĞĐƵƌĞŝƚƚŽĂŶŽƉĞŶĂƌĞĂŽŶ
ͻ ĚũƵƐƚDĂdžŝŵƵŵ^ƉĞĞĚ͕ZĞŐĞŶĂŶĚĐĐĞůĞƌĂƚŝŽŶƚŽĚĞƐŝƌĞĚƐĞƚƚŝŶŐƐ͘
ͻ ƚŚĞĂƐŚ͘
dƵƌŶƚŚĞ>ŽĐŬKƵƚ<ĞLJĨƌŽŵƚŚĞ
>ŽĐŬƉŽƐŝƚŝŽŶƚŽƚŚĞ
hŶůŽĐŬ
ƉŽƐŝƚŝŽŶ͘
ͻ dƵƌŶƚŚĞ>ŽĐŬKƵƚ<ĞLJƚŽƚŚĞ >ŽĐŬ ƉŽƐŝƚŝŽŶƚŽůŽĐŬŝŶƚŚĞƐĞƚƚŝŶŐƐĂŶĚƌĞŵŽǀĞƚŚĞ<ĞLJĨƌŽŵƉƌŽŐƌĂŵŵĞƌ͘
ͻͻ WůƵŐƚŚĞ
Ğ ŶĚŽĨ
ƚ ŚĞ
d&ŝŶZƚ Ž
ƚ ŚĞϴ
WŝŶĐŽŶŶĞĐƚŽƌŽŶ
ŚĞ,ĂƌŶĞƐƐ͘
ĚũƵƐƚD
ĂdžŝŵƵŵ
^KƉĞĞĚ͕
ĞŐĞŶ
ĂŶĚĐĐĞůĞƌĂƚŝŽŶ
ƚŽĚƚ ĞƐŝƌĞĚ
ƐĞƚƚŝŶŐƐ͘
EKd͗dŚĞ<ĞLJĂůůŽǁƐƚŚĞŽƉĞƌĂƚŽƌƚŽůŽĐŬƚŚĞƐĞƚƚŝŶŐƐŽŶƚŚĞŽŶƚƌŽůůĞƌ͘KŶĐĞ
ƚ ŚĞKd&ŝƐůŽĐŬĞĚŽƌƵŶƉůƵŐŐĞĚĨƌŽŵƚŚĞŽŶƚƌŽůůĞƌƚŚĞ
ƐĞƚƚŝŶŐƐĐĂŶŶŽƚďĞĐŚĂŶŐĞĚ͘dŚĞKd&ƐĞƚƚŝŶŐǁŝůůĂůƐŽĐŚĂŶŐĞƚŚĞsĞŚŝĐůĞ͛ƐZĞǀĞƌƐĞŽƉĞƌĂƚŝŽŶƐ͘
ͻ dƵƌŶƚŚĞ>ŽĐŬKƵƚ<ĞLJƚŽƚŚĞ
>ŽĐŬ ƉŽƐŝƚŝŽŶƚŽůŽĐŬŝŶƚŚĞƐĞƚƚŝŶŐƐĂŶĚƌĞŵŽǀĞƚŚĞ<ĞLJĨƌŽŵƉƌŽŐƌĂŵŵĞƌ͘
EKd͗dŚĞ<ĞLJĂůůŽǁƐƚŚĞŽƉĞƌĂƚŽƌƚŽůŽĐŬƚŚĞƐĞƚƚŝŶŐƐŽŶƚŚĞŽŶƚƌŽůůĞƌ͘KŶĐĞ
ƚ ŚĞKd&ŝƐůŽĐŬĞĚŽƌƵŶƉůƵŐŐĞĚĨƌŽŵƚŚĞŽŶƚƌŽůůĞƌƚŚĞ
ƐĞƚƚŝŶŐƐĐĂŶŶŽƚďĞĐŚĂŶŐĞĚ͘dŚĞKd&ƐĞƚƚŝŶŐǁŝůůĂůƐŽĐŚĂŶŐĞƚŚĞsĞŚŝĐůĞ͛ƐZĞǀĞƌƐĞŽƉĞƌĂƚŝŽŶƐ͘
7 K LV 0RW 5DW LQ J VSHFLILFD
7 K LV/DEHO
dŽƉƌŽŐƌĂŵƚŚĞĚĞƐŝƌĞĚƐĞƚƚŝŶŐƐŝŶƚŽƚŚĞĐŽŶƚƌŽůůĞƌ͗
7 K LV 0RW 5DW LQ J VSHFLILFD
ͻ dƵƌŶƚŚĞ>ŽĐŬKƵƚ<ĞLJĨƌŽŵƚŚĞ
>ŽĐŬƉŽƐŝƚŝŽŶƚŽƚŚĞ hŶůŽĐŬ ƉŽƐŝƚŝŽŶ͘
ͻ ĚũƵƐƚDĂdžŝŵƵŵ
^ƉĞĞĚ͕ZĞŐĞŶĂŶĚĐĐĞůĞƌĂƚŝŽŶƚŽĚĞƐŝƌĞĚƐĞƚƚŝŶŐƐ͘
7 K LV/DEHO
ϭϵ
ͻ dƵƌŶƚŚĞ>ŽĐŬKƵƚ<ĞLJƚŽƚŚĞ >ŽĐŬ ƉŽƐŝƚŝŽŶƚŽůŽĐŬŝŶƚŚĞƐĞƚƚŝŶŐƐĂŶĚƌĞŵŽǀĞƚŚĞ<ĞLJĨƌŽŵƉƌŽŐƌĂŵŵĞƌ͘
EKd͗dŚĞ<ĞLJĂůůŽǁƐƚŚĞŽƉĞƌĂƚŽƌƚŽůŽĐŬƚŚĞƐĞƚƚŝŶŐƐŽŶƚŚĞŽŶƚƌŽůůĞƌ͘KŶĐĞƚ ŚĞKd&ŝƐůŽĐŬĞĚŽƌƵŶƉůƵŐŐĞĚĨƌŽŵƚŚĞŽŶƚƌŽůůĞƌƚŚĞ
ƐĞƚƚŝŶŐƐĐĂŶŶŽƚďĞĐŚĂŶŐĞĚ͘dŚĞKd&ƐĞƚƚŝŶŐǁŝůůĂůƐŽĐŚĂŶŐĞƚŚĞsĞŚŝĐůĞ͛ƐZĞǀĞƌƐĞŽƉĞƌĂƚŝŽŶƐ͘
7 K LV 0RW 5DW LQ J VSHFLILFD
ϭϵ
7 K LV/DEHO
ϭϵ
23
NAVITAS SERIES 36-48V
DC MOTOR CONTROLLER
Navitas Vehicle Systems Ltd.
Installation Manual
NAVITAS
SERIES
440A-600A
/ 36-48V
NAVITAS
SERIES
36-48V
DC MOTOR CONTROLLER
Installation Manual
ATTENTION: The Controller’s default is set for Shunt Wound Motors and will need to be
re-programmed to a Series Motor using the OTF Programmer (Not included).
SERIES Controller Configuration can only be done on Controllers with SW 8.3 or greater.
ATTENTION: The Controller’s default is set for Shunt Wound Motors and will need to be
re-programmed to a Series Motor using the OTF Programmer (Not included).
SERIES Controller Configuration
can only be done on Controllers with SW 8.3 or greater.
Instructions
for:
Club Car SERIES (Resistive Throttle)
E-Z-GO SERIES (Inductive Throttle)
Instructions for:
Club Car SERIES (Resistive Throttle)
E-Z-GO SERIES (Inductive Throttle)
MAKE SURE TO READ and FOLLOW these Instructions & the Controller Installation & Service
Manual Instructions when installing and operating this Controller and Vehicle!
MAKESURE
SURE
TO READ
and FOLLOW
these Installation
& Service
Instructions
MAKE
TO READ
and FOLLOW
these Instructions
& the Controller
Installation
& Servicewhen
installing
this
Controller
Manual Instructions when installing and operating this Controller and Vehicle!
24
CONTROLLER MOUNTING
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specifica
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WARNINGS the
below
canPositive
damage
sure to
Main
• Make
Cable
on the
Vehicle’s
Battery
the Vehicle
and/or
cause
SERIOUS
INJURYSystem.
OR DEATH!
and
Negative
Before removing the Controller take a photo or note the Wiring Layout on the Original Controller.
Make sure that the groups of wires stay together. Use electrical tape on the Positive and Negative Cables to protect against shorting.
(A) Remove the Bolts holding in the original Controller.
(B) Install the New Controller using the original Bolts and/or the Self Tapping Screws included.
MAKE SURE THE CONTROLLER IS SECURELY MOUNTED!
Install Location 1
Horizontal Mounting
(Club Car)
B
B
A
B
Install Location 2
Vertical Mounting
(Club Car)
Note: If old
controller had A2
bar. Remove that
wire from the cart.
Install Location 3
Vertical Mounting
(E-Z-GO)
Note: If old
controller had A2
bar. Bolt both wires
together and wrap
with tape or shrink
tubing.
2
25
CONTROLLER
CONTROLLER WIRING
WIRING
CClub
C
ar
D
S
SER
I
ES
(
R
esi
st
i
ve
Thr
ot
t
l
e)
llnst
Club
Car
DS
SERIES
(Resistive
Throttle)
Installation
lub C arD S SER IES (R esistive Throttle)
nstal
alllat
atiion
on
Note: Car must use a diode.
(A) to (D) see page 5.
(A) to (D) see page 25
5. .
(E) Connect the Terminal Wires as shown in the chart and photo below for numbers 1 to 3 and CN1 to CN3. NOTE: CN4 & 5 are not required.
(E) Connect the Terminal Wires as shown in the chart and photo below for numbers 1 to 3 and CN1 to CN3. NOTE: CN4 & 5 are not required.
(F) Connect the 20 Pin to 20 Pin Plug Connector to the Controller and then to the Harness (Connector #1). Make sure to align the locking hole on the
(F) Connect
theand
20 the
Pin locking
to 20 Pinclip
Plug
to side.
the Controller
and this
thenconnector
to the Harness
(Connector
#1).sides.
Make sure to align the locking hole on the
Controller
side
onConnector
the Harness
GENTLY push
in to place
on both
Controller side and the locking clip on the Harness side. GENTLY push this connector in to place on both sides.
(G)
Connect the
the 10 PinOTF
OTF Plug Connector
to the Harness
(# 2*).
NOTE:
The OTF is optional but is required to program the Controller for a Series
(G)
to the Harness
NOTE:
The OTF
is optional.
(G)Connect
Connect the1010Pin
Pin OTFConnector
Plug Connector
to the (#2*).
Harness
(# 2*).
NOTE:
The OTF is optionalTip:
but is
required to program
the Controller
a Series
Alternatively
Connect
4 to the for
keyswitch
Cart. (H) Re-attach the Vehicle’s Main Battery Positive and Negative Cables.
(H)
Re-attach
the Vehicle’s
Main Battery
Negative
Cart.
(H) Re-attach
the Vehicle’s
MainPositive
Batteryand
Positive
andCables.
Negative Cables.
to shut down controller when key is off.
The C ontrollerw illneed to be congured fora Series C art.See instructions page 6:“C onguration M ode Instructions”
The C ontrollerw illneed to be congured fora Series C art.See instructions page 6:“C onguration M ode Instructions”
. onnector Plug & Terminal Wire Location
Harness Part
C
. onnector Plug & Terminal Wire Location
Harness Part
C
Plug
PlugConnector
Connectorfrom
from
Controller
Controller
“On
“OnThe
TheFly”
Fly”Programmer
Programmer
22 OTF
88Pin
OTF
Pin *(Not included)
*(Not included)
SilverWolf
SilverWolf4WD
4WDSystem
System
33 4WD
33Pin
Extension
4WD
Pin (WH03500
(WH03500
Extension Cable)
Cable)
Not
Used
*(Optional.
*(Optional.Not
Notincluded)
included)
Ring
Attach
Ring
Attachto
tothe
theBattery
Battery side
side of
of
44 Vehicle
Vehicle Terminal
Terminal the
theSolenoid
Solenoid(Large
(LargePost)
Post)
CN1
Terminal Key
Key(usually
(usuallyRed)
Red)
CN1 Vehicle
Vehicle Terminal
CN2
Terminal +5V
+5V(usually
(usuallyGreen)
Green)
CN2 Vehicle
Vehicle Terminal
CN3
Terminal Throttle
Throttle(usually
(usuallyYellow)
Yellow)
CN3 Vehicle
Vehicle Terminal
CN4
Terminal Throttle
CN4 Vehicle
Vehicle Terminal
ThrottleGND
GND(Not
(Notrequired)
required)
CN5
Terminal REV
CN5 Vehicle
Vehicle Terminal
REVInput
Input(Not
(Notrequired)
required)
11
Vehicle
Vehicle 20
20Pin
Pin
GG
4
4
2*
2*
3*
3*
11
CN5
CN1
CN4 CN3
CN5 CN4
CN3 CN2
CN2 CN1
E
To
ToOTF
OTFProgrammer
Programmer
Connector
Connector
+DUQHVV
+DUQHVV
CN1
CN5
CN4 CN3
CN5 CN4
CN3 CN2
CN2 CN1
11
20
20Pin
Pinto
to20
20Pin
PinPlug
PlugConnector
Connector
Part
Part##40-000517
40-000517
FF
FF
Make
Makesure
surethe
theLocking
LockingTab
Tabon
on
the
thePlug
PlugConnector
Connectorlocks
locksininto
to
thetab
tabon
onthe
the+DUQHVV.
+DUQHVV.
the
Make
Makesure
surethe
theSlot
Sloton
onthe
the
+DUQHVV
+DUQHVVlocks
locksin
into
tothe
thetab
tab
ontheController
Controller
onthe
F2
F2
X
X
NOTE:F1
F1&&F2
F2Posts
Postsare
arenot
notused
used on
on SERIES
SERIES Carts
Carts
Cars
NOTE:
3
3
26
BB-
M
M
B+
F1
F1
X
X
CONTROLLER WIRING
E-Z-GO
(Inductive
Throttle)
Installation
E-Z-G O SER
IES (ISERIES
nductive
Throttle)
Installat
ion
(A) to (D) see page25.
5.
Note: Car must use a diode.
(E) Connect the Terminal Wires as shown in the chart and photo below for numbers 1 to 3, 5 and CN1 to CN3. NOTE: CN4 & 5 are not required.
(F) Connect the 20 Pin to 20 Pin Plug Connector to the Controller and then to the Harness (Connector #1). Make sure to align the locking hole on the
Controller side and the locking clip on the Harness side. GENTLY push this connector in to place on both sides.
Tip:
Alternatively
Connect
4 to the
(G) Connect the 10 Pin OTF Plug Connector to the Harness (# 2*). NOTE: The OTF is optional.but
is required
to program
the Controller
forkeyswitch
a Series Cart.
to shut down controller when key is off.
(H) Re-attach the Vehicle’s Main Battery Positive and Negative Cables.
The Controller will need to be configured for a Series Cart. See instructions page 6: “Configuration Mode Instructions”
3DUW 10-000667
Harness
Connector Plug & Terminal Wire Location
1
Vehicle 20 Pin
2
OTF
8 Pin
3
4WD
3 Pin
4
Vehicle Terminal
Ring
5
CN1
CN2
CN3
CN5
Vehicle
Vehicle
Vehicle
Vehicle
Vehicle
6 Pin
Terminal
Terminal
Terminal
Terminal
Plug Connector from
Controller
“On The Fly” Programmer
*(Not included)
SilverWolf 4WD System
Not Used
(WH03500
Extension Cable)
*(Optional. Not included)
Attach to the Battery side of
the Solenoid (Large Post)
Alternative TXT Connector
Key
GND (usually White)
Throttle (usually Black)
REV Input (Not required)
4
2*
2*
3*
3
1
5
CN5 CN4 CN3 CN2 CN1
CN5 CN4 CN3 CN2 CN1
G
E
To OTF Programmer
CN5 CN4 CN3 CN2 CN1
Connector
+DUQHVV
1
20 Pin to 20 Pin Plug Connector
Part # 40-000517
FF
F
Make sure the Locking Tab on
the Plug Connector locks in to
the tab on the +DUQHVV.
Make sure the Slot on the
+DUQHVV locks in to the tab
onthe Controller
F2
F2
X
X
NOTE: F1 & F2 Posts are not used on SERIES cars.
Carts
4
27
BB-
M
M
B+
B+
F1
F1
XX
INSTALLATION INSTRUCTIONS
INSTALLATION INSTRUCTIONS
6(5,(6&OXE&DU (=*2,QVWDOODWLRQ
6(5,(6&OXE&DU (=*2,QVWDOODWLRQ
D
D
X
X
X
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C
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D
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A
BB
XX
B
X
*
(A)
Connect
Motoruse
Cable
(M)*from the original Controller to the M Post on the Controller using a M8 Bolt, Lock Washer and Flat Washer.
Note:
Carthe
must
a diode.
*
(B) Connect the Main Positive Power Cables from the Original Controller to the B+ Post on the New Controller using a M8 Bolt, Lock Washer
(A) Connect the Motor Cable (M) from the original Controller to the M Post on the Controller using a M8 Bolt, Lock Washer and Flat Washer.
and Flat Washer.
(B) Connect the Main Positive Power Cables from the Original Controller to the B+ Post on the New Controller using a M8 Bolt, Lock Washer
Note * This photo shows the 4 SilverWolf 4WD Battery Power Cables installed. They are for the Silverwolf 4WD Kit and are not included with
and Flat Washer.
this kit (Optional).
Note ** This
shows
thethe
4 SilverWolf
4WD Battery
Power
Cables
installed.
They are
the Silverwolf 4WD
Kit and
are
not included with
Note
Thisphoto
photo
shows
4 4WDCables
Battery
Power
Cables
installed.
They
for for
aonprevious
Kit and
now
discontinued.
(C) Connect
the
Main
Negative
Power
from
the Original
Controller
to
the are
B- Post
the New 4WD
Controller
using
a M8
Bolt, Lock Washer
this kit (Optional).
and Flat Washer.
(C) Connect the Main Negative Power Cables from the Original Controller to the B- Post on the New Controller using a M8 Bolt, Lock Washer
(X) The F1 and F2 Posts are not used on this Vehicle.
and Flat Washer.
(D) Connect the Ring Terminal from the Harness (#4 On previous page) to the Battery side of the Solenoid.
(X) The F1 and F2 Posts are not used on this Vehicle.
ForConnect
the next
steps
see
page
3 for(#4
Club
Car and
page
for E-Z-GO;
(D)
the Ring
Terminal
from
the Harness
On previous
page)
to the4Battery
side of the Solenoid.
For the next steps see page 22
3 for
4 E-Z-GO.
for E-Z-GO;
forClub
ClubCar
Car,and
andpage
23 for
Torque Specifications
F1 & F2Specifications
6 mm Bolt 60 in-lbs/ 5ftlbs/ 6.8Nm
Torque
B-/M/B+
in-lbs/5ftlbs/
12.5ftlbs/
16.9Nm
F1 & F2 8
6 mm Bolt 150
60 in-lbs/
6.8Nm
B-/M/B+ 8 mm Bolt 150 in-lbs/ 12.5ftlbs/ 16.9Nm
Note when replacing controllers with an A2 terminal:
• If there is one wire on the A2, follow it back and remove it from the
vehicle.
dotonot
need this
The
ControllerYou
will need
be configured
for a wire.
Series Cart. See instructions below: “Configuration Mode Instructions”
Note: An OTF Programmer is required for the Configuration process.
The Controller will need to be configured for a Series Cart. See instructions below: “Configuration Mode Instructions”
• If An
it OTF
hasProgrammer
two wires
on the
A2,Configuration
bolt the process.
2 wires together and wrap them up.
Note:
is required
for the
Or alternatively,
remove
bothconfigured
wires andand
replace
them with
single
wire
After
the Controller
has been
the Throttle
has abeen
calibrated,
the Vehicle is ready for
between
the
F/R
and
the
motor.
the
“Controller
Pre-Drive
Test”
see
Page
17
in
the
Controller
Installation/Service
After the Controller has been configured and the Throttle has been calibrated, theManual.
Vehicle is ready for
the “Controller Pre-Drive Test” see Page 17 in the Controller Installation/Service Manual.
5
5
28
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specifica BEFORE PROCEEDING^ĞƌǀŝĐĞŽĨƚŚĞŽŶƚƌŽůůĞƌDƵƐƚďĞĚŽŶĞďLJĂƚƌĂŝŶĞĚŐŽůĨĐĂƌƚĞĐŚŶŝĐŝĂŶ͘
CHECK THE FIRMWARE VERSION! IT MUST BE SW8.3 or GREATER!
*This Label m
Note: The list below shows some possible issues when the Controller does not show a Flash Code Error. These issues are often related to
ĞĨŽƌĞƚƌŽƵďůĞƐŚŽŽƚŝŶŐ
ƚŚĞŽŶƚƌŽůůĞƌ͖
Note:
The
list
below
shows
some
possible
issues
whenManual.
the Controller
does
show a Flash
the Vehicle. Always check the Manufacturers
Service
- and refer
to not
the Bluetooth
App.Code Error. These issues are often related to
Always check the Manufacturers Service Manual.
ͻ DĂŬĞƐƵƌĞƚŚĞZƵŶͬdŽǁ^ǁŝƚĐŚŝƐŝŶƚŚĞdŽǁƉŽƐŝƚŝŽŶ
the Vehicle.
Controller
is NOT
getting
power power.
(SERIES) or is in Sleep Mode (SHUNT). See Bluetooth App.
Thismeans
meansthethe
Controller
is NOT
getting
* This
SOLID GREEN LIGHT IS OFF
E'Z
ͻ
dŚĞ<ĞLJŝƐƚƵƌŶĞĚK&&
* This means the Controller is NOT getting power.
SOLID GREEN LIGHT IS OFF
ISSUE
CAUSE
HOW TO CHECK
ͻ DĂŬĞƐƵƌĞ>>ĚƌŝǀĞǁŚĞĞůƐĂƌĞŽĨĨƚŚĞŐƌŽƵŶĚĂŶĚƚŚĞǀĞŚŝĐůĞŝƐƐƵƉƉŽƌƚĞĚǁŝƚŚũĂĐŬƐƚĂŶĚƐ͘
ͻ
ISSUE
CAUSE
HOW TO CHECK
Green Light on • Check the wiring to the
• Is the Black wire with Ring Terminal connected to the Battery +
ͻ dŚĞŽŶƚƌŽůůĞƌŝƐƐĞĂůĞĚĂŶĚĐĂŶŶŽƚďĞŽƉĞŶĞĚĨŽƌƐĞƌǀŝĐĞ͘KƉĞŶŝŶŐƚŚĞŽŶƚƌŽůůĞƌǁŝůůsŽŝĚƚŚĞ
No Solid
No
Green Light on
tĂƌƌĂŶƚLJ
theSolid
Controller
the Controller
•
Check
the wiring
to the
Controller
and Solenoid
Controller and Solenoid
• Positive
Is the Black
with
Ring Terminal connected to the Battery +
sidewire
of the
Solenoid.
sideallofthe
thewiring
Solenoid.
• Positive
Check that
connections to the Controller are correct and
WZ>/D/EZz
• dZKh>^,KKd/E'
Check
tight. that all the wiring connections to the Controller are correct and tight.
to CN5 wires on the Harness and check for Solid
• Disconnect
the CN1
• Disconnect
CN5 wires
the Harness
check forone
Solid
Green Light.the
IF CN1
Yes to
Check
wiringon
connections
byand
reinstalling
at a
Green
time. Light. IF Yes Check wiring connections by reinstalling one at a
time.
dŽŽůƐZĞƋƵŝƌĞĚ͗
ŝŐŝƚĂů DƵůƚŝŵĞƚĞƌ
SOLID GREEN LIGHT IS ON
SOLID GREEN LIGHT IS ON
* This means the Controller is getting power.
* This means the Controller is getting power.
ISSUE
CAUSE
HOW TO CHECK
ISSUE
CAUSE
HOW TO CHECK
voltage
• With Key ON and Direction Selector in Forward measure the
Vehicle / Motor not
• Faulty Foot Switch on the
• With
Key PIN
ON and
Selector
in Forward
measure
the voltage
Vehicle / Motor not
• Faulty
Foot Switch on the
between
CN1 Direction
and Battery
Negative
B-. Should
see battery
voltage
moving
Throttle
/^^h
WK^^/>
h^^
,Kt
dK
,<
between
PIN CN1
and Battery
B-. Should see battery voltage
moving
• Throttle
Faulty Key Switch
when Throttle
is pressed
and Negative
OV when released.
sĞŚŝĐůĞͬ ŽŶƚƌŽůůĞƌ ͻ ••ZhEͬdKtŽĨĨ͘
^ǁŝƚĐŚ
Faulty Micro
Key Switch
when
isŝŶZhEƉŽƐŝƚŝŽŶ͘
pressed
and OVSwitches
when released.
Faulty
Switches on ͻ • ZhEͬdKt
If Not:Throttle
check
Key
Switch, Micro
and Foot Switch.
ĚŽĞƐŶŽƚƉŽǁĞƌ ƵƉ͘ ͻ •ŝƐĐŚĂƌŐĞĚͬ
ĂĚĂƚƚĞƌŝĞƐ
ŶĞĞĚƐƚŽďĞ
ĂƚůĞĂƐƚ
ƉŽǁĞƌƵƉͿ
Faulty Micro
Switches on ͻ • ŚĞĐŬĂƚƚĞƌLJWĂĐŬǀŽůƚĂŐĞ;/ƚ
If Not: check Key Switch, Micro
Switches and
FootϯϭsƚŽ
Switch.
Directional
Selector
ͻ tŝƌŝŶŐĂŶĚ
ŽŶŶĞĐƚŽƌƐ
ͻ ŚĞĐŬůůtŝƌĞƐĨŽƌĚĂŵĂŐĞŽƌůŽŽƐĞĐŽŶŶĞĐƚŝŽŶƐ͘
Directional
Selector
Measure Pin 2 of the 3Connector
Pin 4WD Connector
on thetoHarness
• Faulty Throttle
on the Harness
Batteryto Battery
ͻ • ŚĞĐŬƚŚĂƚƚŚĞƉŝŶƐĂƌĞĨƵůůLJƐĞĂƚĞĚŝŶƚŚĞŽŶŶĞĐƚŽƌƐ;ďLJƚƵŐŐŝŶŐ
Harness
to Battery
Measure Pin
2Should
of the see
3 Pin0-5V
4WDthat
Connector
the
• Negative
• Faulty Throttle
B-.ŝŶĚŝǀŝĚƵĂůǁŝƌĞƐͿĂŶĚƚŚĂƚ
varies
Throttle
position.
ůŝŐŚƚůLJŽŶƚŚĞ
ƚ ŚĞwith
on
ŽŶŶĞĐƚŽƌƐĂƌĞ
ĨƵůůLJ
Negative
B-. Should
see
0-5V
that varies
with
Throttletoposition.
(Series
module
does
the
translation
from
ITS
throttle
0-5V)
ƐĞĂƚĞĚĂŶĚůŽĐŬĞĚŝŶƚŽƉůĂĐĞ͘
(Series module does the translation from ITS throttle to 0-5V)
ͻ •ŽƌƌĞĐƚǀŽůƚĂŐĞĂƚŽŶƚƌŽůůĞƌ
Faulty Directional Selector ͻ • ŚĞĐŬƚŚĞǀŽůƚĂŐĞĂƚƚŚĞŽŶƚƌŽůůĞƌďĞƚǁĞĞŶнĂŶĚͲ;ŝƚƐŚŽƵůĚďĞƚŚĞ
With Key ON and Directional Selector in Forward measure the voltage
• Faulty Directional Selector • ƉĂĐŬǀŽůƚĂŐĞͿ͘
With
Key ON
Directional
in Forward
measure the
between
the and
B+ and
M on theSelector
Controller
while depressing
thevoltage
between
the
B+
and Mshould
on the
depressing
Throttle.
voltage
thewhile
Throttle.
ͻ ŚĞĐŬ
ƚ ŚĞǀThe
ŽůƚĂŐĞďĞƚǁĞĞŶ
Wvary
ŝŶController
ϭϬwith
ŽĨƚ ŚĞ
s ĞŚŝĐůĞ
DŽĚƵůĞ,the
ĂƌŶĞƐƐ͛Ɛ
Throttle.
The voltage
should
vary with
• ϮϬWŝŶŽŶŶĞĐƚŽƌĂŶĚƚŚĞͲ͘;/ƚƐŚŽƵůĚďĞƉĂĐŬǀŽůƚĂŐĞͿ͘
If the voltage
at B+ and
M changes
andthe
theThrottle.
wheels do not turn check
If
voltage atSelector
B+ and by
M changes
andathe
wheels do
ͻ &ĂƵůƚLJ,ĂƌŶĞƐƐ
thethe
Directional
performing
Continuity
Testnot turn check
ͻ • ZĞƉůĂĐĞ,ĂƌŶĞƐƐ
the Directional Selector by performing a Continuity Test
• Faulty Motor
• Do Low Voltage Motor Check.
/ĨƚŚĞƌĞŝƐƉĂĐŬǀŽůƚĂŐĞĂƚƚŚĞŽŶƚƌŽůůĞƌďĞƚǁĞĞŶн͕WŝŶϭϬĂŶĚͲƌĞƉůĂĐĞƚŚĞŽŶƚƌŽůůĞƌĂŶĚ
• Faulty Motor
• Do Low Voltage Motor Check.
ƌĞͲƚĞƐƚ͘
Vehicle
is moving Slowly • OTF Programmer is set too • Make sure the OTF is Unlocked and adjust the Speed Knob to a higher
Vehicle is moving Slowly • OTF
Programmer
is
set
too
•
Make
sure the OTF is Unlocked and adjust the Speed Knob to a higher
setting.
Low
&>^,KdZKh>^,KKd/E'
setting.
Low
dŚŝƐŽŶƚƌŽůůĞƌŚĂƐďŽƚŚĂ'ZE
>ĂŶĚĂZ>^ƚĂƚƵƐ>ŝŐŚƚƚŚĂƚǁŝůůŝŶĚŝĐĂƚĞƚŚĞƐƚĂƚƵƐŽĨƚŚĞ
ŽŶƚƌŽůůĞƌ͘
• Faulty
Throttle
• Calibrate the Throttle (see Configuration Instructions above)
/ƚŝƐůŽĐĂƚĞĚŝŶƐŝĚĞƚŚĞŽŶƚƌŽůůĞƌĂŶĚŝƐǀŝƐŝďůĞƚŚƌŽƵŐŚƚŚĞdŽƉŽǀĞƌǁŚĞŶƚŚĞŽŶƚƌŽůůĞƌŝƐƉŽǁĞƌĞĚ͘
• Faulty Throttle
• Calibrate the Throttle (see Configuration Instructions above)
EŽƚĞ͗dŚĞǀĞŚŝĐůĞ͛ƐƌĞǀĞƌƐĞďƵnjnjĞƌǁŝůůĂůƐŽĐŚŝƌƉƚŚĞĨůĂƐŚĐŽĚĞŝŶƚŚĞĞǀĞŶƚŽĨĂĨĂƵůƚ͘
• Selector Switch stuck in
• Check Reverse Micro Switch.
• Selector
• Check Reverse Micro Switch.
EŽƚĞ͗/ĨƚŚĞKƉƚŝŽŶĂů͞KŶƚŚĞ&ůLJ͟WƌŽŐƌĂŵŵĞƌǁĂƐƉƵƌĐŚĂƐĞĚŝƚŝƐĂůƐŽĞƋƵŝƉƉĞĚǁŝƚŚĂ'ZE>^ƚĂƚƵƐ>ŝŐŚƚ͘dŚŝƐůŝŐŚƚǁŝůůŝŶĚŝĐĂƚĞ
Reverse Switch stuck in
Reverse ŝŶ 'ZEŽŶůLJ͘
ƚŚĞƐĂŵĞ&ůĂƐŚŽĚĞƐĞdžĐĞƉƚƚŚĞLJǁŝůůďĞ
>^ddh^
>/',d,Zd
GREEN
LIGHT IS FLASHING
GREEN LIGHT IS FLASHING
ISSUE
CAUSE
'ZE>
ISSUE
CAUSE
* This means the Controller is NOT getting power. с^K>/
* This means the Controller is NOT getting power.
HOW TO CHECK
>
HOWZ
TO CHECK
Internal
•
'ZEIssue s,/> ^dd DK ^ddh^
Internal Issue
•
^ƚĂŶĚďLJ dƵƌŶ<ĞLJKE
džϮ <zK&&
Ύ
<zKE
ZĞĂĚLJ
ZĞĂĚLJƚŽƵƐĞ͊
ΎŽŶƚƌŽůůĞƌǁŝůůĞŶƚĞƌƐůĞĞƉŵŽĚĞŝĨŬĞLJŝƐŽĨĨ͘
>ŝŐŚƚǁŝůůĨůĂƐŚϮdžĨŽƌϱĐLJĐůĞƐďĞĨŽƌĞŐŽŝŶŐƚŽƐůĞĞƉ͘
с&>^,/E'
Contact Navitas Vehicle Systems Ltd. or Dealer to Return the Controller
Z Navitas
s,/>
^dd
DK
^ddh^
Contact
Vehicle
Systems Ltd. or Dealer
to Return
the Controller
for
a Complimentary
Diagnostic.
^ĞĞ &ůĂƐŚ ŽĚĞ
ŚĂƌƚ EĞdžƚ WĂŐĞ
ƌƌŽƌ
for a Complimentary
Diagnostic.
y &ĂƵůƚ͊
Z >^ƚĂƚƵƐ >ŝŐŚƚĐŽŶƚĂŝŶƐ ĂϮĚŝŐŝƚĐŽĚĞ͖
yDW>͗
ϭ^
сϭͲϮ&ůĂƐŚ ŽĚĞ
EKd͗dŚĞƌĞǁ ŝůůďĞĂϮƐĞĐŽŶĚƉĂƵƐĞďĞĨŽƌĞƚŚĞĞƌƌŽƌĐŽĚĞƌĞƉĞĂƚƐŝƚƐĞůĨ͘
30
ϮϬ
7
/ E ^ d >> d/ K E ͬ ^ Zs / DEh>
dZKh>^,KKd/E'
E'Z
&ĂŝůƵƌĞ ƚŽ ĨŽůůŽǁ ƚŚĞ tĂƌŶŝŶŐƐ ŝŶ ƚŚŝƐ DĂŶƵĂů ĐĂŶ ĚĂŵĂŐĞ ƚŚĞ sĞŚŝĐůĞ ĂŶĚͬŽƌ ĐĂƵƐĞ ^Z/Kh^ /E:hZz
KZ d,͘
^ĞƌǀŝĐĞŽĨƚŚĞŽŶƚƌŽůůĞƌDƵƐƚďĞĚŽŶĞďLJĂƚƌĂŝŶĞĚŐŽůĨĐĂƌƚĞĐŚŶŝĐŝĂŶ͘
ĞĨŽƌĞƚƌŽƵďůĞƐŚŽŽƚŝŶŐ ƚŚĞŽŶƚƌŽůůĞƌ͖
ͻ
ͻ
ͻ
ͻ
ͻ
DĂŬĞƐƵƌĞƚŚĞZƵŶͬdŽǁ^ǁŝƚĐŚŝƐŝŶƚŚĞdŽǁƉŽƐŝƚŝŽŶ
dŚĞ<ĞLJŝƐƚƵƌŶĞĚK&&
DĂŬĞƐƵƌĞ>>ĚƌŝǀĞǁŚĞĞůƐĂƌĞŽĨĨƚŚĞŐƌŽƵŶĚĂŶĚƚŚĞǀĞŚŝĐůĞŝƐƐƵƉƉŽƌƚĞĚǁŝƚŚũĂĐŬƐƚĂŶĚƐ͘
dŚĞŽŶƚƌŽůůĞƌŝƐƐĞĂůĞĚĂŶĚĐĂŶŶŽƚďĞŽƉĞŶĞĚĨŽƌƐĞƌǀŝĐĞ͘KƉĞŶŝŶŐƚŚĞŽŶƚƌŽůůĞƌǁŝůůsŽŝĚƚŚĞ
tĂƌƌĂŶƚLJ
WZ>/D/EZz dZKh>^,KKd/E'– See Bluetooth App
dŽŽůƐZĞƋƵŝƌĞĚ͗
ŝŐŝƚĂů DƵůƚŝŵĞƚĞƌ
/^^h
WK^^/> h^^
sĞŚŝĐůĞͬ ŽŶƚƌŽůůĞƌ ͻ ZhEͬdKtŽĨĨ͘
ĚŽĞƐŶŽƚƉŽǁĞƌ ƵƉ͘ ͻ ŝƐĐŚĂƌŐĞĚͬ ĂĚĂƚƚĞƌŝĞƐ
ͻ tŝƌŝŶŐĂŶĚŽŶŶĞĐƚŽƌƐ
,Kt dK ,<
ͻ
ͻ
ͻ
ͻ
ZhEͬdKt ^ǁŝƚĐŚ ŝŶZhEƉŽƐŝƚŝŽŶ͘
ŚĞĐŬĂƚƚĞƌLJWĂĐŬǀŽůƚĂŐĞ;/ƚ ŶĞĞĚƐƚŽďĞĂƚůĞĂƐƚϯϭsƚŽƉŽǁĞƌƵƉͿ
ŚĞĐŬůůtŝƌĞƐĨŽƌĚĂŵĂŐĞŽƌůŽŽƐĞĐŽŶŶĞĐƚŝŽŶƐ͘
ŚĞĐŬƚŚĂƚƚŚĞƉŝŶƐĂƌĞĨƵůůLJƐĞĂƚĞĚŝŶƚŚĞŽŶŶĞĐƚŽƌƐ;ďLJƚƵŐŐŝŶŐ
ůŝŐŚƚůLJŽŶƚŚĞŝŶĚŝǀŝĚƵĂůǁŝƌĞƐͿĂŶĚƚŚĂƚƚ ŚĞŽŶŶĞĐƚŽƌƐĂƌĞĨƵůůLJ
ƐĞĂƚĞĚĂŶĚůŽĐŬĞĚŝŶƚŽƉůĂĐĞ͘
ͻ ŽƌƌĞĐƚǀŽůƚĂŐĞĂƚŽŶƚƌŽůůĞƌ ͻ ŚĞĐŬƚŚĞǀŽůƚĂŐĞĂƚƚŚĞŽŶƚƌŽůůĞƌďĞƚǁĞĞŶнĂŶĚͲ;ŝƚƐŚŽƵůĚďĞƚŚĞ
ƉĂĐŬǀŽůƚĂŐĞͿ͘
ͻ ŚĞĐŬƚ ŚĞǀŽůƚĂŐĞďĞƚǁĞĞŶWŝŶϭϬŽĨƚ ŚĞs ĞŚŝĐůĞDŽĚƵůĞ,ĂƌŶĞƐƐ͛Ɛ
ϮϬWŝŶŽŶŶĞĐƚŽƌĂŶĚƚŚĞͲ͘;/ƚƐŚŽƵůĚďĞƉĂĐŬǀŽůƚĂŐĞͿ͘
ͻ &ĂƵůƚLJ,ĂƌŶĞƐƐ
ͻ ZĞƉůĂĐĞ,ĂƌŶĞƐƐ
/ĨƚŚĞƌĞŝƐƉĂĐŬǀŽůƚĂŐĞĂƚƚŚĞŽŶƚƌŽůůĞƌďĞƚǁĞĞŶн͕WŝŶϭϬĂŶĚͲƌĞƉůĂĐĞƚŚĞŽŶƚƌŽůůĞƌĂŶĚ
ƌĞͲƚĞƐƚ͘
&>^,KdZKh>^,KKd/E' – See Bluetooth App
dŚŝƐŽŶƚƌŽůůĞƌŚĂƐďŽƚŚĂ'ZE >ĂŶĚĂZ>^ƚĂƚƵƐ>ŝŐŚƚƚŚĂƚǁŝůůŝŶĚŝĐĂƚĞƚŚĞƐƚĂƚƵƐŽĨƚŚĞŽŶƚƌŽůůĞƌ͘
/ƚŝƐůŽĐĂƚĞĚŝŶƐŝĚĞƚŚĞŽŶƚƌŽůůĞƌĂŶĚŝƐǀŝƐŝďůĞƚŚƌŽƵŐŚƚŚĞdŽƉŽǀĞƌǁŚĞŶƚŚĞŽŶƚƌŽůůĞƌŝƐƉŽǁĞƌĞĚ͘
EŽƚĞ͗dŚĞǀĞŚŝĐůĞ͛ƐƌĞǀĞƌƐĞďƵnjnjĞƌǁŝůůĂůƐŽĐŚŝƌƉƚŚĞĨůĂƐŚĐŽĚĞŝŶƚŚĞĞǀĞŶƚŽĨĂĨĂƵůƚ͘
EŽƚĞ͗/ĨƚŚĞKƉƚŝŽŶĂů͞KŶƚŚĞ&ůLJ͟WƌŽŐƌĂŵŵĞƌǁĂƐƉƵƌĐŚĂƐĞĚŝƚŝƐĂůƐŽĞƋƵŝƉƉĞĚǁŝƚŚĂ'ZE>^ƚĂƚƵƐ>ŝŐŚƚ͘dŚŝƐůŝŐŚƚǁŝůůŝŶĚŝĐĂƚĞ
ƚŚĞƐĂŵĞ&ůĂƐŚŽĚĞƐĞdžĐĞƉƚƚŚĞLJǁŝůůďĞ ŝŶ 'ZEŽŶůLJ͘
>^ddh^ >/',d,Zd
с^K>/
'ZE>
Ύ
'ZE
s,/> ^dd DK ^ddh^
^ƚĂŶĚďLJ dƵƌŶ<ĞLJKE
džϮ <zK&&
<zKE
ZĞĂĚLJ
ZĞĂĚLJƚŽƵƐĞ͊
ΎŽŶƚƌŽůůĞƌǁŝůůĞŶƚĞƌƐůĞĞƉŵŽĚĞŝĨŬĞLJŝƐŽĨĨ͘
>ŝŐŚƚǁŝůůĨůĂƐŚϮdžĨŽƌϱĐLJĐůĞƐďĞĨŽƌĞŐŽŝŶŐƚŽƐůĞĞƉ͘
Z >
Z
s,/> ^dd
^ĞĞ &ůĂƐŚ ŽĚĞ ŚĂƌƚ EĞdžƚ WĂŐĞ
DK
ƌƌŽƌ
Z >^ƚĂƚƵƐ >ŝŐŚƚĐŽŶƚĂŝŶƐ ĂϮĚŝŐŝƚĐŽĚĞ͖
с&>^,/E'
^ddh^
y &ĂƵůƚ͊
yDW>͗
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31
– See Bluetooth App
FLASH
CODES
FLASH CODE
MESSAGE
DESCRIPTION
SOLUTION
HOW TO CHECK
1-1
Voltage Issue:
Batteries
Batteries are empty
or too low.
• Recharge Batteries
• Use Battery Load Tester to verify battery
conditon after charging.
• Check for bad or damaged
batteries
• Check Battery Cables are
not loose or damaged.
1-1
1-1
Voltage Issue:
Batteries
Voltage Issue:
Solenoid
(Contactor)
Batteries too full
• Check Solenoid
•Batteries cannot take a
charge. Check the batteries,
one or more may be bad
Damaged Solenoid or
loose wiring
• Confirm the solenoid is
working properly. Change
solenoid if needed.
• Connect Volt Meter to Main + and - on
batteries. (Use alligator clips). Measure
the voltage while dirving to see if voltage
drops.
• Attach Volt Meter to the + and - on
the controller. if the voltage drops at the
Controller but not the battery then the
solenoid might be bad.
• Use a Battery Load Tester to verify the
battery condition after charging.
•Put vehicle in Neutral. Measure
voltage on main terminals (high current
connections) of the solenoid. Depress
throttle and listen for solenoiod to click.
If solenoid clicks and the voltage does not
drop to 0v between the main terminals,
replace solenoid.
• If solenoid does not click, measure the
voltage across the small termials of the
solenoid when the throttle is depressed. It
should read battery voltage. If it reads the
battery voltage the solenoid is bad. If it
does not ready the battery voltage check
vehicle wiring.
1-2
Temperature
(Controller)
Performance is
limited because the
controller is hot
• Let vehicle cool off, system
is overworked
1-3
Charger
Interlock
Charger is connected
• Disconnect the Charger
Vehicle charging port
may be wet or bad
• Dry and clean the charger
port
Club Car OnBoard
Computer (OBC) is in
sleep mode or bad
* Depress the throttle twice
to wake up the OBC
• Check temperature of the controller
with a non- contact temperature sensor
* Replace Charger port on
vehicle
1-4
Temperature
(Controller)
Performance is
limited because the
motor is hot
• Let vehicle cool off, system
is overworked
• Check temperature of the motor with a
non- contact temperature sensor
1-5
BDI (Battery
Discharge
Indication)
The battery level is
less than 20% SOC
(State of Charge)
• Charge batteries
• The vehicle will automatically be put
into Low Speed Mode
Warning! Continued use may damage the
batteries!
32
– See Bluetooth App
FLASH
CODES
FLASH CODE
MESSAGE
DESCRIPTION
SOLUTION
HOW TO CHECK
2-1
Switch Fault
Both the FWD &
REV signal came on
at the same time
• Check and replace FWD &
REV switch
• Check for loose wires. If there is a diode
across the small terminals, check at it is
installed correctly and not shorted.
2-2
Solenoid
(Contactor)
Solenoid colil is
pulling too much
current
• Check for loose wires or
a short across the small
terminals on the solenoid.
• Check for loose wires. If there is a diode
across the small terminals, check at it is
installed correctly and not shorted.
• Replace solenoid.
• Test solenoid by measuring the resistance
across the small terminals of the solenoid.
The resistance should be grater than 48
OHMS.
2-3
Reverse
Buzzer / OTF
LED
Over Current on
the Reverse Buzzer
/ OTF LED circuit.
• Find and corect the short
circuit.
• Replace reverse buzzer
• Replace OTF
• Unplug OTF and check if Flash Code Error
stops on the controller
• Check for a short circuit in the wiring near
the reverse buzzer on in the buzzer itself.
2-4
Controller
not Precharging
Abnormally low
voltage on the
controller between
B+ and B-
• Clean and dry off controller
• Visually check for debris or moisture on
the controller terminals and wires. (There
may be short acrss the B+ and B- terminals.)
Cables/Connector
• Check voltage
• Check all the wires are
connected to the controller
• Test Cables at the
Controller.
DO NOT replace the
controller until all of
the “HOW TO CHECK”
diagnostics regarding
Flash Code 2-4 have been
completed and the motor
has been tested for short
circuits!
* Check the wires are not damaged
• Check the B+ and the F1/F2 wires are not
shorted to the frame or each other. (B+/F1,
B+/F2, F1/F2)
• Check that no accessories (Lights, stereos,
etc) are using the frame as ground.
• Remove all cables except B- from the
controller..
• Tape cables so they do not touch each
other or the vehicle frame. Controller
harness should remain plugged into the
controller.
• Move Run/Tow Switch to Run, Turn on
Keyswitch, depress the throttle. If 2-4 Flash
Code returns, replace the controller.
• Otherwise there is a wiring problem.
Reconnect wires one at a time starting with
the B+ (Turn off RUN/TOW switch each
time) until 2-4 Flash Code returns. This will
indicate source of wiring issue.
2-5
Throttle Supply
Failure
+5V to the throttle
is low
• Disconnect throttle from
harness
• If error clears, then check throttle.
2-6
Loss of Field
Current
Field current on
the controller is 0A
• Check Field Cables
• Remove field cables from controller,
measure across F1 and F2 in Forward with
the throttle down. Should read battery pack
voltage. Switch to Reverse, press throttle.
Should read battery pack voltage. If either
test fails, replace controller.
33
– See Bluetooth App
FLASH
CODES
FLASH CODE
MESSAGE
2-8
Field Shorted
DESCRIPTION
SOLUTION
HOW TO CHECK
Short detected on
field circuit
• Check to see if field wires
are touching motor case.
• Check for shorts from F1 and F2 to Battery
- and frame.
• Disconnect F1 and F2 from controller. Turn
on keyswitch and see if fault remains. If it
doesn’t, replace the motor.
– See Bluetooth App
34
ACCESSORIES
Bluetooth® Apps for TSX 3.0
Visit www.navitasvs.com/contact to request access
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APPENDIX C
Pinout for YAMAHA G19/22 (MORIC) Controller
B+ Battery Pos & Motor A2
10
1
20 POS Molded
TSX Connector
TSX harness for Yamaha G19/G22
10
1
20
1
8 POS Molex
39-29-9083
Navitas Part Number: 40-000514
W
Pinout: CPn= Wn
Reserved
3 POS Molex
39-30-1039
P1: KEY
P2: THROTTLE IN
P3: FWD IN
Navitas PN: 10-000686
OnTheFly Programmer
P1: +12V PF
P2: OTF Regen
P3: OTF speed
P4: OTF acceleration
P5: +5V PF
P6: OTF Lock
P7: REV BUZ
P8: AGND
To OEM vehicle harness
Yamaha G19/G22
23 POS TE
776228-1
P1: (CP10) Logic Power
P2: (CP5) Charger Interlock
P3: (CP17) Foot Switch
P4: (CP7) Fwd In
P5: (CP6) Rev In
P6: (CP8) Key
P7: (CP15) Throttle In
P8: (CP18) GND Poly
P9: (CP11) +5V
P10: (CP19) Reverse Buzzer
P11: (CP20) Line Contactor
P12: NA
P13: NA
P14: (CP4) Speed Sensor
P15: (CP16) +12V
P16: (CP18) GND Poly
P17: (CP20) Line Contactor
P18: NA
P19: NA
P20: NA
P21: NA
P22: NA
P23: NA
CP=Controller Pinout
38
Battery Neg
20
F2 Motor F2
1
P1: RED
P2: RED/BLACK
P3: WHITE
P4: WHITE/BLACK
P5: GREEN
P6: GREEN/BLACK
P7: BLUE
P8: BLUE/BLACK
P9: BROWN
P10: BROWN/BLACK
P11: ORANGE
P12: ORANGE/BLACK
P13: PURPLE
P14: PURPLE/BLACK
P15: PINK
P16: PINK/BLACK
P17: YELLOW
P18: YELLOW/BLACK
P19: GREY
P20: GREY/BLACK
1
Motor A1
B-
P1: OTF LOCK
P2: XCAN_N
P3: XCAN_P
P4: SPEED SENSOR SIGNAL
P5: CHARGER INTERLOCK
P6: REV IN
P7: FWD IN
P8: KEY
P9: GND
P10: LOGIC POWER
P11: +5V EXT
P12: OTF ACCELERATION
P13: OTF SPEED
P14: OTF REGEN
P15: THROTTLE IN
P16: +12V POLY
P17: FOOT SWITCH
P18: GND POLY
P19: REVERSE BUZZER
P20: LINE CONTACTOR
1
M
Navitas TSX DC Shunt Controller
F1 Motor F1
Diagrams and other updates available at: NavitasVS.com/support
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APPENDIX E
INSTALLATION INSTRUCTIONS
CPC/CVG (SEVCON) Installation Cont’d
INSTALLATION/ SERVICE MANUAL
Pinout for Controller
Motor A1
B-
Battery Neg
20
F2 Motor F2
1
1
20 POS Molded
TSX Connector
10
20 POS Molded
TSX Connector
P1: RED
P2: RED/BLACK
P3: WHITE
P4: WHITE/BLACK
P5: GREEN
P6: GREEN/BLACK
P7: BLUE
P8: BLUE/BLACK
P9: BROWN
P10: BROWN/BLACK
P11: ORANGE
P12: ORANGE/BLACK
P13: PURPLE
P14: PURPLE/BLACK
P15: PINK
P16: PINK/BLACK
P17: YELLOW
P18: YELLOW/BLACK
P19: GREY
P20: GREY/BLACK
1
8 POS Molex
39-29-9083
Navitas Part Number: 40-000592
TSX harness for CPC Negative Logic
Navitas PN: 40-000517
16 POS Molex
39-28-1163
P1: (CP16) +12V PF
P2: (CP14) OTF Regen
P3: (CP13) OTF speed
P4: (CP12) OTF acceleration
P5: (CP11) +5V PF
P6: (CP1) OTF Lock
P7: (CP19) REV BUZ
P8: (CP18) AGND
Navitas PN: 10-000686
OnTheFly Programmer
1
M
Navitas TSX DC Shunt Controller
J7 / CP
B+ Battery Pos & Motor A2
P1: OTF LOCK
P2: XCAN_N
P3: XCAN_P
P4: SPEED SENSOR SIGNAL
P5: CHARGER INTERLOCK
P6: REV IN
P7: FWD IN
P8: KEY
P9: GND
P10: LOGIC POWER
P11: +5V EXT
P12: OTF ACCELERATION
P13: OTF SPEED
P14: OTF REGEN
P15: THROTTLE IN
P16: +12V POLY
P17: FOOT SWITCH
P18: GND POLY
P19: REVERSE BUZZER
P20: LINE CONTACTOR
To OEM vehicle harness
P1: (CP8/10) Key/Logic Power
P2: Forward In (Negative)
P3: Reverse In (Negative)
P4: Foot Switch (Negative)
P5: Charger Interlock (Negative)
P6: N/C
P7: N/C
P8: (CP20) Line Contactor
P9: (CP19) Reverse Buzzer
P10: (CP15) Throttle In
P11: N/C
P12: (CP16) +12V Poly
P13: N/C
P14: N/C
P15: N/C
P16: (CP4) Speed Sensor
40
F1 Motor F1
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Wiring Diagram For Club Car Series
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Pos +
Run/Tow
Switch
F1
Diode
5(9 ,1
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Interlock
Key Switch
P12: OTF ACCELERATION
P13: OTF SPEED
P14: OTF REGEN
P15: THROTTLE IN
P16: +12V POLY
P17: FOOT SWITCH
P18: GND POLY
P19: REVERSE BUZZER
P20: LINE CONTACTOR
Direction Switch
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3
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3
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11
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Warranty Document #05-000102
Navitas Vehicle Systems Ltd. warrants that the products sold to Customer by Navitas will be free from defect in materials
and workmanship as noted below, from the date of manufacturing shipping of the product, subject to the terms and
conditions in this Limited Warranty.
1.
2.
3.
TSX, TSX2.0,TSX3.0, Separately Excited Models, TPM Permanent Magnet Models, TAC AC Induction Models – 24 months
TSE Series Models, PSE Hydraulic Models, CTL Series Models – Lessor of 12 months or 4,000 hours
MAC AC Motor – 12 months
If, during the applicable warranty period, (i) Navitas is advised in writing as to a defect in a Navitas product; (ii) such
product is returned to a receiving point designated by Navitas; and (iii) an examination of such product discloses to Navitas’
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 Navitas, Navitas 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 Navitas under this warranty shall become the
property of Navitas and must be returned to Navitas properly packed to prevent physical damage.
Navitas 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 Navitas product for a particular application. Navitas shall be
entitled to rely exclusively upon such representation in furnishing any product to Customer.
TSX and TAC Products Application is for Golf Car and LSV Vehicles with speeds of up to of 25MPH. Users must comply with
Federal, County and Municipal Bylaws & Regulations when operating vehicles.
Warranty Limitations
The foregoing warranty constitutes Navitas’ 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. Navitas 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 Navitas 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 Navitas products sold to Customer are intended to be used only in the application specified by Customer to Navitas.
Any other use renders the Limited Warranty expressed herein and all implied warranties null & void and same are hereby
excluded. Under no circumstances shall Navitas 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 Navitas 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 Navitas and Customer. Except as stated, any purported modification of this limited warranty shall be null and void.
June 2019
Distributed by:
Navitas Vehicle Systems Ltd. (Navitas)
Waterloo, Ontario N2L 6A7 Canada
Fax 519-725-1645
www.NavitasVS.com
29
43
Navitas Vehicle Systems Ltd.
500 Dotzert Crt.
Waterloo, ON Canada
N2L 6A7
Navitas Vehicle Systems (US) Ltd.
P.O BOX 691934 Orlando, FL
32869 United States
1-844-576-2499
NavitasVS.com