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MASTERFLUX GOLF CART 48V AIR-CONDITIONER …

MASTERFLUX golf CART 48V AIR-CONDITIONER AND HEAT PUMP INSTALLATION MANUAL CLUB CAR DS Electric Model 71481 REV-REL (4/26/06) 171481 REV-REL (4/26/06) 2 HAZARDOUS MATERIAL WARNING! BATTERY- EXPLOSION HAZARD. Do not smoke while near vehicle while it is being serviced! Keep sparks and flames away from vehicle when servicing. Service only in well ventilated area. BATTERY- POISON. Contain acid- causes severe burns! Avoid contact with skin, eyes of clothing. Battery acid can cause blindness- wear full-face shield and rubber gloves while working with or near batteries. If contact occurs: External- Flush with Water.

masterflux golf cart 48v air-conditioner and heat pump installation manual club car ds electric model 71481 rev-rel (4/26/06)

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Transcription of MASTERFLUX GOLF CART 48V AIR-CONDITIONER …

1 MASTERFLUX golf CART 48V AIR-CONDITIONER AND HEAT PUMP INSTALLATION MANUAL CLUB CAR DS Electric Model 71481 REV-REL (4/26/06) 171481 REV-REL (4/26/06) 2 HAZARDOUS MATERIAL WARNING! BATTERY- EXPLOSION HAZARD. Do not smoke while near vehicle while it is being serviced! Keep sparks and flames away from vehicle when servicing. Service only in well ventilated area. BATTERY- POISON. Contain acid- causes severe burns! Avoid contact with skin, eyes of clothing. Battery acid can cause blindness- wear full-face shield and rubber gloves while working with or near batteries. If contact occurs: External- Flush with Water.

2 Call Physician immediately. Internal- Drink large quantities of milk or water followed by Milk of Magnesia or vegetable oil. Call Physician immediately after ingestion. Eyes- Flush with water for 15 minutes. Call Physician immediately. Battery is to be disconnected while installation is performed. CAUTION! To be serviced only by technicians trained in mechanical or electrical repair. Technician must use appropriate instructions, including this Installation Guide when servicing this unit. Installation Guide instructions are to be followed exactly. Heed all CAUTION, WARNING and DANGER statements given in this Guide as well as those posted on the vehicle and unit. Before servicing vehicle, turn key switch to OFF and set parking brake.

3 Wear safety glasses when servicing vehicle. Do not service vehicle when it is running. Allow motor to cool before serving vehicle. Servicing vehicle when motor is HOT can result is Severe Burns. Insulated tools should be used when working near batteries or electrical connections. Failure to do so could result in dangerous and damaging electrical shorts. Make sure wiring and wiring harness are properly routed and secured. Failure to properly route and secure wiring could result in vehicle malfunction, property damage, personal injury or death. TOOLS REQUIRED FOR INSTALLATION PHILLIPS HEAD SCREW DRIVER 7/16 OPEN END WRENCH 1/2 OPEN END WRENCH 1/2 SOCKET 7/16 SOCKET RATCHET PLIERS WIRE CUTTERS BOLT CUTTERS OTHER TOOL SUITABLE FOR CUTTING THROUGH INCH BOLT WIRE CRIMPING TOOL DRILL WITH 1 HOLE CUTTER (OPTIONAL) STANDARD PARTS 48V AIR-CONDITIONING- (P/N CRS0000480) OR AIR-CONDITIONING/HEAT PUMP UNIT- (P/N CRS0000485) DS MOUNTING KIT P/N LP183 o KIT CONSISTS OF.

4 BASKET REAR OF CARTSIDE SUPPORT BRACKETS BAG SUPPORT BRACKET FRONT OF CART BASKET CONDENSER UNIT MOUNTING BRACKET- RIGHT CONDENSER UNIT MOUNTING BRACKET- LEFT FRONT OF CART LEFT CONDENSER MOUNTING BRACKET RIGHT CONDENSER MOUNTING BRACKET ID STAMP CONDENSER UNIT MOUNTING BRACKETS 71481 REV-REL (4/26/06) 3 CONDUIT/FLEX LINE MOUNTING BRACKET SLOTS FOR MOUNTING TO REAR ROOF SUPPORT REAR OF CART HOLE FOR MOUNTING TO EVAPORATOR BRACKET HOLE FOR QUICK TIE FLEX LINE MOUNTING BRACKET EVAPORATOR MOUNTING BRACKET-SHOWN BELOW SIDE FLANGES FACING UPWARD. FLANGELEFT SIDE MOUNTING HOLES FRONT OF CARTACCESS HOLES PEM NUT FOR MOUNTING FLEX LINE BRACKET REAR OF CART-KNOB AND NOZZLES OF EVAPORATOR UNIT EVAPORATOR UNIT MOUNTING BRACKET-POSITIONED AS MOUNTED IN DS CART GROOVED RUBBER GROMMET WITH INCH HOLE INCH WASHERS- 4 -20 LOCK NUTS 4 -20 SCREW 1 SHORT ZIP TIES 25 LONG ZIP TIES- 10 FLEXIBLE DRAINAGE TUBE-7 FT 3/8 RING TERMINALS-2 #8-32X TRUSS HEAD SCREWS and INCH WASHERS-4 EACH --INSTALLATION-- NOTE - BEFORE BEGINNING INSTALLATION- 1.

5 READ ALL INSTRUCTIONS AND WARNINGS 2. SET PARKING BRAKE 3. CHOCK CART WHEELS 4. DISCONNECT BATTERY 5. KEEP ALL HARDWARE THAT IS REMOVED FROM CART DURING INSTALLATION- IT WILL BE REINSTALLED 71481 REV-REL (4/26/06) 4 EVAPORATOR SECTION INSTALLATION 1. REMOVE EVAPORATOR FROM BOX. CAREFULLY UNCOIL TUBE BUNDLE AND PLACE EVAPORATOR WITH BOLTS FACING UP ON A NON-ABRASIVE, STABLE SURFACE. 2. PLACE EVAPORATOR MOUNTING BRACKET ON EVAPORATIVE UNIT WITH THE SIDE FLANGES OF THE BRACKET FACING UPWARDS AS SHOWN. LONG FLANGE ON BRACKET SHOULD ALIGN WITH THE SIDE OF THE EVAPORATOR UNIT OPPOSITE THE NOZZLES AND KNOB OF UNIT AND WILL BE FACING DOWNWARDS TOWARDS UNIT. 3. SLIDE PROVIDED WASHERS OVER BOLTS. 4. INSTALL AND TIGHTEN -20 LOCK-NUTS PROVIDED IN MOUNTING KIT 5.

6 CUT BOLTS SUCH THAT BOLT END IS NEARLY FLUSH WITH NUT. EVAPORATIVE UNIT WITH BRACKET INSTALLED SHOWING STUDS TO BE CUT JUST ABOVE THE MOUNTING NUT CUT 6. REMOVE THE 4 LOCK NUTS FROM THE BOLTS AT FRONT END OF golf CART ROOF SUPPORT (2 ON EACH SIDE OF SUPPORT). KEEP BOLTS, THEY WILL BE USED IN THE NEXT STEP. REMOVE ROOF SUPPORT BOLTS AND LOCK NUTS 7. WITH NOZZLES AND KNOB FACING TOWARD THE PASSENGER COMPARTMENT, ALIGN THRU HOLES OF BRACKET FLANGES WITH THE HOLES IN THE SUPPORT FROM WHICH THE BOLTS HAD BEEN REMOVED. INSERT BOLTS PREVIOUSLY REMOVED THRU THE BRACKET HOLES INTO THE ROOF SUPPORT HOLES FROM WHICH THEY HAD PREVIOUSLY BEEN REMOVED.

7 TIGHTEN LOCK NUTS BACK ONTO BOLTS. USE ACCESS HOLES IN BRACKET TO INSERT BOLTS ACCESS HOLE REINSTALLING ROOF SUPPORT BOLTS AND NUTS THROUGH EVAPORATOR MOUNTING BRACKET 71481 REV-REL (4/26/06) 5 MOUNTED EVAPORATOR UNIT AS VIEWED FROM INSIDE OF CART INSTALL FLEX-LINE BUNDLE SUPPORT BRACKET 1. REMOVE BOLTS AND LOCK NUTS FROM REAR PASSENGER SIDE ROOF SUPPORT BRACKET. 2. HOLD FLEX-LINE BRACKET IN ONE HAND WHILE INSERTING BOLTS THROUGH BRACKET AND ROOF SUPPORT AS SHOWN. TIGHTEN LOCK NUTS ONTO THROUGH BOLTS. REINSTALLING REAR ROOF SUPPORT BRACKETS THROUGH SLOTS IN FLEX LINE MOUNTING BRACKET 3. INSERT -20 SCREW PROVIDED WITH MOUNTING KIT THROUGH HOLE IN FLEX LINE BRACKET INTO PEM NUT IN EVAPORATOR MOUNTING BRACKET, AS SHOWN.

8 TIGHTEN. -20 SCREW INSTALLATION OF -20 SCREW FROM KIT THROUGH HOLE IN FLEX LINE MOUNTING BRACKET INTO PEM NUT OF EVAPORATOR MOUNTING BRACKET. 71481 REV-REL (4/26/06) 6 CONDENSING UNIT INSTALLATION 1. REMOVE SEAT FROM golf CART. REMOVE SCREWS HOLDING SEAT BACK ONTO CART REMOVING SEAT REMOVING SCREWS FROM SEAT BACK 2. REMOVE BASKET SUPPORT BOLT, NUT AND WASHER FROM BAG SUPPORT BRACKET AT REAR OF CART. REMOVE BOLTS AND NUTS FROM ENDS OF SIDE SUPPORTS. REMOVE BAG SUPPORT BRACKET FROM REAR OF CART. BAG SUPPORT BRACKET BASKET SUPPORT BOLT, NUT WASHER REAR BAG SUPPORT BOLT, NUT AND WASHER BAG SUPPORT BRACKET INSTALLED BAG SUPPORT BRACKET REMOVED 3.

9 REMOVE BASKET BOLTS, WASHERS AND NUTS FROM SIDE SUPPORTS. REMOVE BASKET. SIDE SUPPORT BOLT, NUT, WASHERS FROM SIDE SUPPORT SIDE SUPPORT MOUNTING HARDWARE BASKET HAS BEEN REMOVED 71481 REV-REL (4/26/06) 7 4. REMOVE SCREWS FROM REAR ACCESS PANEL BEHIND SEAT BACK. REMOVE PANEL. REAR ACCESS PANEL REMOVING SCREWS FROM REAR ACCESS PANEL REMOVING REAR ACCESS PANEL 5. REMOVE BOLTS FROM ROOF STRUTS BY REACHING INTO OPENING EXPOSED WHEN REAR ACCESS PANEL WAS REMOVED. HOLD ROOF MOUNT BOLT HEAD WITH FINGER WHILE TURNING NUT 6. INSTALL RIGHT AND LEFT CONDENSER SUPPORT BRACKETS AS SHOWN, FIRST SLIDING THE FRONT END OF THE BRACKET UNDER THE SEAT SUPPORTS THEN SLIDING THE BACK OF THE BRACKETS UNDER THE ROOF STRUTS.

10 SEAT BACK SUPPORT ROOF SUPPORT BRACKET LIFT SEAT BACK SUPPORT, SLIDE BRACKET UNDER LIFT ROOF STRUT, SLIDE BRACKET UNDER BRACKET 71481 REV-REL (4/26/06) 8 7. REMOVE CONDENSING UNIT FROM BOX. LIFT RIGHT ROOF STRUT, SLIDE TUBING BUNDLE UNDER ROOF STRUT. CAREFULLY REST CONDENSING UNIT ON FENDER COVER. LIFT RIGHT ROOF STRUT, SLIDE BUNDLE UNDER STRUT REST CONDENSER UNIT ON RIGHT FENDER 8. REINSTALL ROOF STRUT BOLTS. TIGHTEN. REINSTALL PLASTIC REAR ACCESS PANEL AND PANEL SCREWS; TIGHTEN SCREWS. REINSTALL ROOF STRUT BOLTS REPLACE ACCESS PANEL 9. PLACE CONDENSING UNIT BETWEEN CONDENSING MOUNTING BRACKETS ALIGN HOLES IN CONDENSING UNIT WITH HOLES IN BRACKETS.


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