Torque 600amp Controller 25-001
Contents
1. 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 Light flashing see the Flash Code Chart Below RED LED Status Light contains a 2 digit code The Ist 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 AT NOX K N Va A NOS isTaLLATCON SERVICE MANUAL X v2 ROUBLESHOOTING FLASH FLASH CODE CODES AES DESCRIPTION SOLUTION HOW TO CHECK ES ON Batte Voltage Issue Batteries Voltage Issue Solenoid Contactor Temperature Controller 1 3 Charger Interlock Temperature Motor Batteries are empty or Batteries too full Damaged Solenoid or loose Wiring Performance is limited because the Controller is Hot Charger is connected Vehicle Charging Port may be wet On Board Computer OBC is in sleep mode Performance is limited because the Motor is Hot Both FWD amp REV signal came on at the same time Recharge Batteries Check for bad or damaged Batteries Check Battery Cables are not loose or damaged2. Distributed Exclusively by Madjax TORGULE 5600A 48V or 36V DC MOTOR CONTROLLER Installation Service Manual 25 O01 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 2Z25 O0O5 36v WIRING HARNESS FOR E Z GO TXT 25 006 WIRING HARNESS FOR YAMAHA DrRive INSTALLATION INSTRUCTIONS Instructions for Club Car Precedent amp 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 d Y NG E A MANUAL AY lt INTRODUCTION TORQUE 600A 48V or 36V DC MOTOR CONTROLLER The owner say operators MUST Read and Understand All Warnings and Instructions in this manual and in the Vehicle Owner perator s Manwal The owner of this vehicle assumes all liability for accidents injuries or damages if the warnings and instructions are not followed Madja Sumes no responsibility for errors or omissions in this manual in regards to liability or damages resulting from the use of pfit 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 A obligation to make these changes on units previously sold d Product and specifi
3. 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 TEIRBILIE 600 AMP 36V Controller using the 3 screws from the original controller Note These Screws will be going into A 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 Connector Plug Location 1 Vehicle 3 Pin Vehicle Harness Connector Vehicle Harness Connector Vehicle Harness Connector Vehicle Harness Connector 2 4Pin EN 4Pin 4 10 Pin DCERDE 0 WH03500 Extension Cable On The Fly Programmer OTF Optional Not included P X N NAN TO 36 36V with Curtis 12060MX Installation cont d ct the Motor ble from th a Controller to the M Post on the THIRBILIE 600A Controller using a M8 Bolt Lock Washer Ai Washer A Consec the Main Positive VA Power Cable from the Vehicle Solenoid along with the 2 SilverWolf 4WD Positive Red Power Cables if e 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 MES
4. Check Solenoid Batteries can not take a charge Check the Batteries one or more Batteries may be bad Confirm the Solenoid is working properly Change Solenoid if required Let Vehicle cool off system is over worked Disconnect the Charger before trying to move Dry and clean the Charger Port Depress the throttle twice to wake up OBC Replace Charger port on Vehicle Let Vehicle cool off system is over worked Check and replace FWD amp REV Switch Use a Battery Load Tester to verify Battery condition after charging Connect Volt Meter to Main C and C on the Batteries Use alligator clips Measure the voltage while driving to see if the voltage drops Attach Volt Meter to 4 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 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 conta
5. 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 fonths 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 or
6. Pin Connector on the Vehicle Module Harness to the TEIRBILIE 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 RUP SU ue Fly Programmer aEMMMMMMME cl JR ni Tw NOTE The Module should be oriented and secured with Zip Ties so that water and debris does not accumulate in the Connectors onnector Plug Location Controller Harness SilverWolf 4WD System WH03500 Extension Cable On The Fly Programmer 4 Vehicle 26 Pin Vehicle Harness Connector E A 207 X4 NG NG Le N Zoo MANUAL A 002 INSTALLATION INSTRUCTIONS N OTF On the Fly Programmer Optional A FAILURE to follow the WARNINGS below can damage AD ANGE the Vehicle and or cause ears OR DEATH By unlocking the programmer with the key and adjusting the top speed acceleration and electronic braking the user has changed the operating behavior of the vehicle The user takes full responsibility when the OTF Programmer is unlocked and changes are made from the Factory Settings Vehicle Module Harness OTF 8 Pin Connector Speed Accel Q yrana E PROGRAMMER row sr NAVITAS Status Speed Top speed Low speed Regeneratio
7. 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 THIRBILIE 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 TORBILIE Controller Post using a Spade Connector and a M6 Bolt Lock Washer and Flat Washer X vu NEST d 5 004 INS ALLATION INSTRUCTIONS XA Install NM op tfie Vehicle Modtle Harness tothe TORQUE Controller Install the 16 Pin Connector from the Vehicle Wiring Harness to the 16 Pin Connector on the Vehicle Module Harness NC If the Vehicle has a SilyerWolf 4WD System connect the Extension Harness from the Main Harness into the 3 Pin Connector on Vehicle Module Harness NOLE The Module should be oriented and secured with Zip Ties so that water and debris does not accumulate in the Connectors a SYBTIONUINOD Now the Vehicle s Main Battery Positive and Negative Cables can be re connected INSTABLATION SERVICE MANUAL NN N INSTALLATION INSTRUCTIONS K Make sure the RUN TOW Switch is in the TOW position Make sure to Disconnect the Main Positive P and C Negative Cable on the Vehicle s Battery System Before removing the original Controller take note or take a photo of the 5 Controller Posts and their corresponding Wires
8. 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 EN KETAN AT ONISERV E MANUAL x X NA ALLATION INSTRUCTIONS Drive with Moric JW2 Installation e Make sure the RUN TOW Switch is in the TOW position DA N G F R e Make sure to Disconnect the Main Positive CP and Negative N Cable on the Vehicle s Battery System D the original Controller take note or take a photo of the 5 Controller Posts and their corresponding Wires Make sure that emove the groups of wires stay together A the Original Vehicle Controller B Install the TORGE 600 AMP Controller using the 3 screws from the original controller CAUTION DO NOT CONNECT ANY WIRES OR CABLES UNTIL AFTER STEP C Do a O 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 b
9. LTAGE LEAD LEAD ad Be ep Fi B 048V approx F2 B 048V approx OTF TROUBLESHOOTING ISSUE CAUSE HOW TO CHECK OTF Knobs do not OTF is Locked E Use Key to unlock E OTF to adjust Controller settings change the Controller OTF Connector Check that the 8 Pin Connector on the OTF is plugged in to the SW settings Vehicle Module Harness OTF Faulty Replace OTF or return for service Settings are not chang OTF not locking in new After adjusting the knobs to the desired settings move the OTF Key ing settings from the fg UNLOCK to the LOCK position The amp LOCK position saves the current settings to the Controller The OTF may now be unplugged and removed from the Vehicle Wem za f f FX b x ACCESSORIES A A A OTF ON THE FLY PROGRAMMER 32 2 E Fad FOR OPTIMAL PERFORMANCE 4 r A lA I A y Accel i 7 hey ex DR v N g ramgd E PROGRAMMER poweneser NAVITAS Status 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 X switch faulty key switch etc e Plug and Play installation Speed adjustability On the Fly from 8 to 25 mph Limited Warranty
10. S Note The list below shows some possible issues when the Controller does not show a Flash Code Error T ese Issues are mainly related o the Vehicle Always check the Manufacturers Service Manual ISSUE CAUSE HOW TO CHECK The Vehicle is moving Batteries are discharged e Re charge the Batteries slower than normal Bad or damaged Motor e Check Motor Faulty Speed Sensor e Unplug Speed Sensor Faulty Throttle e 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 OTF programmer is locked Connect the OTF Programmer unlock it and adjust to desired speed at low speed Note Lock OTF Programmer before removing it or the settings may change Vehicle is shutting Check Vehicle Wiring for down loose connections Check the OBC On Board Check the OBC by referring to the OBC section in the Computer manufacturers service manual Oscillations or bumpy Motor compatibility Check that the Motor is on the TEIQBILIE recommended Motors list feel when driving Vehicle feels sluggish Battery Cables are Upgrade the Power Cables to at least 4AWG after driving for a while undersized Faulty Controller e Controller malfunction e Use a Digital Multimeter set to Diode mode 9 e Remove all Wires and Cables on Controller e Use Controller Diode Test Chart below to test the Controller CONTROLLER DIODE TEST BLACK RED VO
11. SilverWolf 4WD System WH03500 Extension Cable 600 AMP Wire Location BLACK Negative Cable from Battery EAE Also Connect SilverWolf BLACK Negative Battery Cables if installed RED Positive Cable from Battery Also Connect SilverWolf RED Positive Battery Cables if installed MAIN BATTERY POSITIVE NOTE F1 amp F2 Field Wires if installed incorrectly the FWD REV Switch will work in opposite direction The TORGUE 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 Ns X ces ran arisen MANUAL AL ATION NSTRUCTIONS e Make sure the RUN TOW Switch is in the TOW position e Make sure to Disconnect the Main Positive CP and C Negative y X Cable on the Vehicle s Battery System 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 TORGUE 600 AMP Controller using the 3 screws from the original controller SEE PHOTOS ON FOLLOWING PAGE C Connect the Motor Cable from the original Controller to the M Post on the TO RGUIE 600A Controller using a M8 Bolt Lock Washer and Flat Washer D Connect the Main Positive Red Power Cable along with the 2 SilverWolf 4
12. Vehicle Module Harness that is attached to the Controller ISSUE POSSIBLE CAUSES HOW TO CHECK Vehicle Controller does RUN TOW off RUN TOW Switch in RUN position not power up e Discharged Bad Batteries Check Battery Pack voltage It needs to be at least 31V to power up e Wiring and Connectors 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 e Correct voltage at Controller 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 e faulty SW Vehicle Module Replace SW Vehicle Module Harness Harness If dh 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
13. WD 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 TEINBILIE 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 TORBILIE 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 p WV E gt muse MANUAL e NA AL ATION INSTRUCTIONS H Install the 25 003 20 Pin Connector on the Vehicle Module Harness to the TO RGUE 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 1 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 WV N f the E has a six 8V Battery TS ifs plastic on Co
14. and or cause SERIOUS INJURY OR DEATH 4 Do not leave children or pets unattended in or near the vehicle e Never drive too fast The Terrain conditions and the operator s skill will determine a safe speed e Drive at a reduced speed and use extra caution when carrying passengers or cargo e Avoid sharp turns and do not accelerate quickly when turning e Always look behind you before and while backing up e Reduce speed when towing and allow more room for stopping and turning e Drive with wheels straight when going up and down hills e Slow down and use brakes when going down hills e Never drive on hills with a slope greater than 15 degrees e Do not drive through fast flowing water or water above the floor of the vehicle e f you must cross shallow water make sure to stop and inspect the area for sudden drop offs large rocks or slippery surfaces Always proceed with caution or choose a safer route e When towing this vehicle make sure the key is turned off the Run Tow switch is in Tow and batteries main power is disconnected e Never exceed the towing capacity rating as specified by the vehicle manufacturer Keep electrical components dry and DO NOT wash with direct stream or power washer e Never re wire by pass or change the wires switches or controller Contact your dealer or the manufacturer if vehicle is not operating correctly e Keep the controller and the area around it clean and free of debris e Vehicle and all pa
15. cations 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 TORQUE 600AMP 48V DC CONTROLLER MEN TORQUE 600AMP 36V DC CONTROLLER MEER 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 NX S WARNINGS NO N f T 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
16. ct 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 AisTaLLATCON sERVICE MANUAL X X NEN SX V2 ROUBLESHOOTING FLASH FLASH CODE CODES abo DESCRIPTION SOLUTION HOW TO CHECK Solenoid Coil takes too Check for loose Wires Check for loose Wires If there is a Diode much current or a short across Small across the Solenoid check that it is not Terminals on the Solenoid shorted Replace main Solenoid Test Solenoid by measuring resistance across the Small Terminals of the Solenoid The resistance should be greater than 48 OHMS High field resistance Check the Motor Field Wires Visually check the Motor Cables by Fi amp F2 to ensure they are following the Cables from the terminals not loose or damaged on the Motor to the Controller Motor may be damaged Measure Motor resistance from F1 to F2 internally and need to be on the Motor It should be around 1 to 2 replaced Ohms If greater than 2 Ohms the Motor has an issue and may need to be replaced Abnormally low volt Clean and dry off the Visually check for debris or moisture on age on the Controller Controller Controller Terminals and Wires There may bea short across the B and B posts Check voltage Check the voltage between B and B on the Controller It should equal the Battery Pack Voltage Check all Wires connected Check that the Wires are not damaged to the Contro
17. der 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 amp 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 limi
18. e connected to the new Controller i RE 1 yA zz f SP Lan n rey No V ce TES M E weeds i s r1 Zee x E A i 2 dw Sea m 1 SEE PHOTO ON FOLLOWING PAGE D Connect the Motor Cable usually white from the original Controller to the M Post on the TORGE 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 THIRBILIE 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 THINRBILIE Controller Post using a Spade Connector and a M6 Bolt Lock Washer and Flat Washer AU Zr X MON INSTARLATION SERVICE MANUAL INSTALLATION INSTRUCTIONS NOTE Use these Spade Connectors on the F2 and F1 posts I Install the 25 006 20
19. ground 1 Move the Run Tow Switch to the Run position 2 Insert and turn Key to ON pL 3 Move Vehicle s FNR switch to the Forward position NANE Pre Drive Test A on the F1 and F2 Wires could be reversed do to Vehicle Wiring and may cause the vehicle to move in the opposite direction as shown on the Switch 4 Step on the Accelerator to test that the Vehicle is operating Repeat this test with the switch in the K Reverse position 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 ACTION RESULT YES NO NM Key Switch Turn Key Switch to ON 1 Green Flash Beep Replace Key Switch 2 jFowad Move Switch to Forward 1 Green Flash Beep Replace FNR Switch 3 Reverse Move Switch to Reverse Green Flash Beep Replace FNR Switch A Foot Switch Slowly depress the Accelerator 1 Green Flash Beep Replace Throttle Sensor or Throttle 5 10096 Throttle Continue to depress Accelerator to Floor 1 Green Flash Beep Replace Throttle Sensor or Throttle Contro
20. ing 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 TQR UE 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 e Ratchet Set e 4 Jack Stands e Open End Wrench Set e Lift Jack 2 ton or more e Electrical Tape e Wheel Chocks e Small Saw or Dremmel tool Club Car Precedent e Multimeter Ne Y f in Ns vit anui A X ALLATION INSTRUCTIONS I v s AMP Vehicle Module Harness AN i f E E NOTE Module shown is for the Club Car Precedent DS and the E Z G0 TXT 48V for Connector location for other Vehicles see the installation instructions for the specific Vehicle K Connector Plug Location 5 Vehicle Harness 1 Venicie 16 Pin emaa On The Fly Programmer 2 orr japin Optional Not included
21. ller Check that the B and Field Wires are not shorted to the Frame or each other Check that no accessories Light Kits Stereos etc are using the Frame as a ground Controller Cables Controller Test Cables at the Controller Remove all Cables except B from the not Controller pre charging 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 Accelerator The Accelerator signal Check Accelerator Wires Check Accelerator Wires and Connections is out of range This Vehicle Module Harness and Measure the voltage between the main can be caused by a Accelerator B and Pin 2 center pin on the 3 pin faulty connection or a AWD connector in the Vehicle Module defective Accelerator Harness The Voltage should start near OV Assembly and move up to a maximum of 5V If not replace Throttle Sensor i e MCOR ATS etc w 3 3 Internal Internal Issue Can NOT be serviced in the field Return to dealer or contact SilverWolf Vehicles Astatcar on service MANUAL XX x XN X V2 TROUBLESHOOTING LASH CODE TROUBLESHOOTING NEWER CODE ERROR
22. ller Drive Test 2 52 0 Before taking the Vehicle for the Final Run Test check for any loose wires or parts that could get caught or damaged This test will show that the Controller is installed and running correctly BEFORE YOU RUN THE FINAL TEST COMPLETE THE FOLLOWING STEPS Lift the Vehicle to allow the Jack Stands to be removed and the Vehicle to be lowered back to the ground Make sure the area around the Vehicle is clear No people children pets or objects that could come in contact with the Vehicle Move the Run Tow Switch to Run Turn the Key to Run and dis engage the Parking Brake Drive the Vehicle to an open area Slowly Accelerate allowing time to get use to the extra power f f L ANA MANU L Ne TROUBLESHOOTING 4 Zz Failure to follow the Warnings in this Manual can damage the Vehicle and or cause SERIOUS INJURY OR DEATH DA N G E R Service of the TORGUE 600A Controller Must be done by a trained golf car technician Before troubleshooting the THRGLIE 600 AMP Controller Make sare the Run Tow Switch is in the Tow position The Key is turned OFF Make sure ALL four wheels are off the ground and the vehicle is supported with jack stands The Controller is sealed and can not be opened for service Opening the Controller will Void the Warranty PRELIMINARY TROUBLESHOOTING Tools Required Vehicle Module Harness Connector Digital Multimeter 7 PIN 10 t Iad This Connector is part of the
23. n 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 e First make sure the Vehicle RUN TOW Switch is in the TOW position and the Key is turned off e The OTF can be mounted on the Vehicle or removed and used as required for programming purposes e The OTF has along 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 get pinched damaged or wet i e Under the Floor Mat in the wiring channel Use the Velcro provided to secure it to an open area on the Dash e Plug the end of the OTF in to the 8 Pin connector on the Vehicle Module Harness As OTF has been set to Factory Settings When changing the settings it must be done in small increments and tested in an open area away from people pets or large objects To program the desired settings into the controller e Turn the lock out key from the Lock to Unlock e Adjust Maximum Speed Regen and Acceleration to desired settings e Turn the key to Lock in the setting and remove the key from programmer 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 A Make sure to remove the key and keep it in a safe and secure spot S X X X N IR e wand 3 NSTAL ATION INSTRUCTIONS N X A CAUTION All 4 Wheels MUST be off the
24. ntroller Wiring Cover will need to be cut out to allow the 20 pin Connector on the Vehicle Module Harness to fit properly E Caution Remove the Vehicle Module Harness before cutting in to the c A2 plastic Cover Tit Measure in from the outer right side of the cover 5 5 inches Use a Q 4 2 wide piece of tape to cover and area 2 wide x 2 5 high 7 Now the Vehicle s Main Battery Positive and Negative Cables can be re connected IN ZZ We X X Nes MEAE quf ALLATION INSTRUCTIONS Re wW 8TXT 48V With Curtis 1206HB Installation e Make sure the RUN TOW Switch is in the TOW position A DA N G b R e Make sure to Disconnect the Main Positive CP and Negative Cable on the Vehicle s Battery System 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 TO ORGUE 600 AMP Controller using the 3 screws from the original controller K C Connect the Motor Cable from the original Controller to the M Post on the T RGUE 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
25. rts must be serviced by qualified service personnel For an authorized service location see your local dealer or visit our web site at www silverwolfmotors com Or call 1 866 410 5297 A D A N D FAILURE to follow the WARNINGS below can damage the Vehicle and or cause SERIOUS INJURY OR DEATH MAKE SURE TO READ and UNDERSTAND the OWNERS INSTALLATION and SERVICE MANUAL and ALL WARNING LABELS with this Controller e Always proceed with caution Keep speed low and do not drive faster than conditions permit The terrain conditions and the operators 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 e 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 ca lt 2 CONTROLLER PARTSLIST Confirm that all parts listed below are with your kit before starting installation This kit includes either the TEINBILIE 600 AMP 48V Controller or the 36V Controller If you are missing parts please contact your local dealer or SilverWolf Vehicles Inc PART DESCRIPTION PARTS QTY 6 M8 Flat Washer Not Show feoooosss 3 Spade Connector 6 3MM for Cl
26. ted 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 7 WWW MYMADJAX CO A y NU CL J
27. ub Car Precedent amp DS E Z GO TXT 36V 20 001010 2 Yamaha Drive 2 AWG 5 16 Ring Terminal Yamaha Drive Only 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 MJ Vehicle Module Harness for Curtis 1510 1515 Controller Club Car Precedent DS W600100 Pe in 2 X E eret mft DN STALLATION 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 N FWD REV Switch and all Wiring needs to be in good condition and operating v to Manufacturers Standards If the system is not working properly this must be repaired before installing this Controller AD A N GER FAILURE to follow the WARNINGS below can damage the Vehicle and or cause SERIOUS INJURY OR DEATH Installation or Servicing of the TORGUE 600 AMP Controller Must be done by a trained golf car technician Before installing or servicing of the TORG UE 600 AMP Controller e 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 test
28. using a M8 Bolt Lock Washer and Flat Washer GyInstall the F1 Field Wire usually green from the original Controller to the F1 Post on the TEINBILIE Controller using a Spade Zonnector 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 TOREBILIE 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 See the CONNECTOR PLUG LOCATION Chart on the previous page and photo 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 TEIRBILIE 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
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