BREEZeasy Kit Installation Instructions
Contents
1. WARNING CONTINUED ON NEXT PAGE Copyright 2006 Club Car Inc Page 2 BREEZeasy Kit Installation Instructions AM1218301 A WARNING Electric vehicles only Electric Carryall Industrial trucks Press the emergency stop switch down before disconnecting or connecting the batteries IQ System and PowerDrive Plus vehicles with serial number 9801 and greater Place Tow Run switch in the TOW position before disconnecting or connecting the batteries Failure to heed this warning could result in a battery explosion or severe personal injury All electric vehicles To avoid unintentionally starting the vehicle disconnect the batteries as shown Figures 2 through 6 starting on page 5 IQ System vehicles After disconnecting the batteries wait 90 seconds for the controller capacitors to discharge Carryall Electric Industrial trucks After disconnecting the batteries discharge the controller capacitors as follows Turn the key switch to ON place the Forward Reverse handle in the REVERSE position and wait until the reverse warning buzzer can no longer be heard When the buzzer stops sounding the controller is discharged PowerDrive System 48 PowerDrive Plus vehicles and 36 volt vehicles with speed controllers After disconnecting the batteries discharge the controller capacitors as follows Turn key switch to ON and place the Forward Reverse handle or switch in REVERSE Slowly depress the accelerator pedal and ke2. black plastic brackets 1 onto each end of the blower 2 until they snap into place Figure 7 Partially attach the upper aluminum brackets 3 to the plastic blower brackets with one nylon bolt 4 and nut at the end nearest the bend as shown Tighten nuts 1 2 turn past snug only DO NOT OVER TIGHTEN With brackets attached to blower slide the bent part of the aluminum bracket under the cowl trim as shown Figure 8 2 5 2 6 Page 6 Figure 7 Assemble Blower Brackets Figure 8 Slide Aluminum Bracket Under Cowl Trim Insert the right and left outside Torx screw to hold the fascia trim and blower in place Before securing the lower aluminum brackets 8 fully thread the Torx screws 9 into the bracket holes Figure 9 Secure the lower brackets to the cowl trim Secure the upper and lower brackets together with remaining nylon bolts 10 washers 11 and nuts 12 as shown COWL TRIM Figure 9 Secure Blower to Cowl BREEZeasy Kit Installation Instructions AM1218301 2 7 Thread the power cable under the plastic ribs of the blower as shown Figure 10 2 8 Lift up cowl trim and route cable under trim as shown Figure 10 and toward passenger side of vehicle Figure 10 Route Power Cable Figure 11 Route Power Cable 2 9 Lift up floormat and route wire in channel to the battery compartment Figure 11 2 10 Secure power wire to vehicle with wire ties provided 2 11 Connect the red wire with in line fuse and mal
3. o BREEZeasy Kit oes Installation Instructions Publication oe These instructions apply to the following kits AM1218301 AM1217301 AM1217501 Edition Code AM1217901 0506A00000 AM1218001 GENERAL INFORMATION AND PRECAUTIONS This publication provides detailed instructions for installing the BREEZeasy on Precedent and DS golf car gasoline and electric vehicles Ensure that all necessary replacement parts the appropriate maintenance and service manual s and this document are available before this kit is installed Thoroughly review this docu ment before any installation procedures are performed The following safety statements relate to specific safety issues and must be read understood and heeded before a kit is installed Failure to do so could result in personal injury and or property damage A DANGER e Battery Explosive gases Do not smoke Keep sparks and flames away from the vehicle and service area Ventilate when charging or operating vehicle in an enclosed space Wear a full face shield and rubber gloves when working on or near batteries e Battery Poison Contains acid Causes severe burns Avoid contact with skin eyes or clothing Antidotes External Flush with water Call a physician immediately Internal Drink large quantities of milk or water Follow with milk of magnesia or vegetable oil Call a physician immediately Eyes Flush with water for 15 minutes Call a physician immediately e Gaso
4. Gasoline vehicle Attach the red wire to the positive battery terminal Attach the black ground wire to the negative battery terminal BREEZeasy Kit Installation Instructions AM1218301 Page 9 4 CONNECT BATTERY CABLES A WARNING e IQ System and PowerDrive Plus vehicles with serial number 9801 and greater Place Tow Run switch in the TOW position before disconnecting or connecting the batteries Failure to heed this warning could result in a battery explosion or severe personal injury e Connect the battery cables positive cable first For gasoline vehicles tighten hardware to 20 ft lb 27 1 N m Figure 1 For electric vehicles tighten hardware to 110 in lb 12 4 N m Figures 2 through 6 starting on page 5 Coat terminals with Battery Terminal Protector Spray CCI P N 1014305 to minimize corrosion e Connect the spark plug wire to the spark plug on gasoline vehicles QUESTIONS Questions or comments regarding these kit instructions should be referred to your local Club Car dealer or distributor Please know your vehicle model and have these kit instructions available when you call Page 10 BREEZeasy Kit Installation Instructions AM1218301
5. WORKING ON VEHICLE Figure 1 Battery Disconnect Gasoline Vehicle Place Tow Run Switch in TOW FRONT OF VEHICLE Place Tow Run switch in the TOW position before disconnecting or connecting battery cables Remove negative cable first Figure 3 Battery Disconnect IQ System and PowerDrive Plus Electric Vehicle FRONT OF VEHICLE Disconnect these battery cables before working on vehicle 6 Remove negative cable first Figure 5 Battery Disconnect PowerDrive System 48 Electric Vehicle BREEZeasy Kit Installation Instructions AM1218301 Remove negative Place Tow Run switch in TOW Maamaa FRONT OF VEHICLE s Place TOW RUN Switch in the TOW position before disconnecting or connecting battery cables Figure 2 Battery Disconnect Precedent Electric Vehicle Place Tow Run Switch in TOW _ Ce FRONT OF VEHICLE Place Tow Run switch in the TOW position before disconnecting or connecting battery cables Remove negative cable first Figure 4 Battery Disconnect PowerDrive Plus Electric Vehicle L S FRONT OF VEHICLE Disconnect these battery cables before working on vehicle Remove negative cable first Figure 6 Battery Disconnect V Glide 36 Volt Electric Vehicle Page 5 2 2 1 2 2 2 3 2 4 INSTALL BREEZeasy ON PRECEDENT Remove the four Torx head screws that secure the cowl trim to the dash Align slots and firmly press the
6. ath For vehicles with cargo beds remove all cargo before raising the bed or servicing the vehicle If the vehicle is equipped with a prop rod ensure that it is securely engaged while bed is raised Do not close bed until all persons are clear of cargo bed area Keep hands clear of all crush areas Do not drop cargo bed lower gently and keep entire body clear Failure to heed this warning could result in severe personal injury or death BREEZeasy Kit Installation Instructions AM1218301 Page 3 TOOLS REQUIRED 7 16 INCH WRENCH 3 16 INCH DRILL BIT 9 16 INCH WRENCH ELECTRICAL TAPE ELECTRIC lt L TORX HEAD SCREWDRIVER HAND DRILL PARTS IN THIS KIT POINTER KNOB LOUVER Ao AM1217701 BLOWER TY 2 i aaa AM1217201 12V Q i AM1217401 24V QTY 1 PRECEDENT BRACKET SET DS BRACKET SET AM1217601 AM1217601 NYLON BOLT lt QTY 4 ALUMINUM BRACKET UPPER ALUMINUM BRACKET o WASHER B Toe 3 1 1 4 INCH 3 4 INCH WASHER NUT LOWER ALUMINUM BRACKET NUT NYLON BOLT NYLONBOLT QTY 2 QTY 4 QTY 4 QTY 2 QTY 2 1 DISCONNECT THE BATTERY CABLES 1 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting on page 2 1 2 Gasoline vehicles Disconnect the spark plug wire from the spark plug Page 4 BREEZeasy Kit Installation Instructions AM1218301 DISCONNECT BATTERY CABLES BEFORE
7. e terminal 12 to the female terminal on the power wire 13 Figure 12 2 12 Electric vehicle Attach the red wire to battery no 1 positive terminal Attach the black ground wire 14 to battery no 2 negative terminal Figure 12 Figure 12 Power Wire Connections Electric Vehicle 2 13 Gasoline vehicle Attach the red wire to the positive battery terminal Attach the black ground wire to the negative battery terminal BREEZeasy Kit Installation Instructions AM1218301 Page 7 3 3 1 3 2 3 3 INSTALL BREEZeasy ON DS Remove screws that secure the key switch housing in place Tilt housing to access entire bottom edge of aluminum dash trim Figure 13 Carefully measure and mark center of dash on aluminum trim Align slots and firmly press the black plastic brackets 1 onto each end of the blower 2 until they snap into place Figure 14 3 4 3 5 3 6 3 7 3 8 Page 8 Figure 13 Key Switch Housing Figure 14 Attach Brackets to BlowerS Center blower and mark hole locations using front slots of plastic brackets 1 2 inch from edge of dash Drill 1 4 inch holes down through aluminum dash trim Secure aluminum plates 3 to blower with 3 4 inch nylon bolts 4 and nuts 5 by inserting bolts up through bottom of plates using rear slots as shown Figure 15 Secure blower to dash by inserting 1 1 4 inch nylon bolts up through dash aluminum plates and blower b
8. ep it depressed until the reverse warning buzzer can no longer be heard When the buzzer stops sounding the controller capacitors are discharged All vehicles Wear safety glasses or approved eye protection when servicing the vehicle or battery charger Wear a full face shield and rubber gloves when working on or near batteries Do not wear loose clothing or jewelry such as rings watches chains etc when servicing the vehicle or battery charger Moving parts Do not attempt to service the vehicle while it is running Hot Do not attempt to service hot engine exhaust system or motor Failure to heed this warning could result in severe burns Use insulated tools when working near batteries or electrical connections Use extreme caution to avoid shorting of components or wiring Lift only one end of the vehicle at a time Use a suitable lifting device chain hoist or hydraulic floor jack with 1000 Ib 454 kg minimum lifting capacity Do not use lifting device to hold vehicle in raised position Use approved jack stands of proper weight capacity to support the vehicle and chock the wheels that remain on the floor When not performing a test or service procedure that requires movement of the wheels lock the brakes If wires are removed or replaced make sure wiring and wire harness are properly routed and secured Failure to properly route and secure wiring could result in vehicle malfunction property damage personal injury or de
9. line Flammable Explosive Do not smoke Keep sparks and flames away from the vehicle and service area Service only in a well ventilated area e Do not operate gasoline vehicle in an enclosed area without proper ventilation The engine produces carbon monoxide which is an odorless deadly poison A WARNING e Follow the procedures exactly as stated in this instruction and heed all DANGER WARNING and CAUTION statements in this instruction as well as those on the vehicle and battery charger Only trained technicians should service or repair the vehicle or battery charger Anyone doing even simple repairs or service should have knowledge and experience in electrical and mechanical repair The appropriate instructions must be used when performing maintenance service or accessory installation Prior to servicing the vehicle or leaving the vehicle unattended turn the key switch OFF remove the key and place the Forward Reverse handle in the NEUTRAL position Chock the wheels when servicing the vehicle Gasoline vehicles only e To avoid unintentionally starting the vehicle Disconnect battery cables negative cable first Figure 1 Page 5 Disconnect the spark plug wire from the spark plug e Frame ground Do not allow tools or other metal objects to contact frame when disconnecting battery cables or other electrical wiring Do not allow a positive wire to touch the vehicle frame engine or any other metal component
10. rackets Figure 16 Figure 15 Install Aluminum Plates Figure 16 Secure Blower to Cowl Reattach key switch housing BREEZeasy Kit Installation Instructions AM1218301 3 9 Thread the power wire under the plastic ribs of the blower Figure 17 Figure 17 Route Power Wire 3 10 Drill a 3 8 inch hole in the cowl where the power wire comes out of the blower See following NOTE and CAUTION NOTE Drill hole as close to fan as possible to limit visibility of hole CAUTION Do not damage any components beneath surface of cowl during drilling operation 3 11 Insert power wire through hole in cowl and route toward passenger side of vehicle Secure power wire to vehicle with wire ties provided while routing to battery compartment 3 12 Connect the red wire with in line fuse and male terminal 7 to the female terminal on the power wire 8 Figure 18 3 13 Electric vehicle with six 8 volt batteries Attach the red wire to battery no 1 positive terminal Attach the black ground wire 9 to battery no 3 negative terminal 3 14 Electric vehicle with four 12 volt batteries Attach the red wire to battery no 1 positive terminal Attach the black ground wire 9 to battery no 2 negative terminal Electric vehicle with six 8 volt A JAS batteries QS 2 5 Electric vehicle x with four 12 volt batteries FRONT OF VEHICLE Figure 18 Power Wire Connections Electric Vehicle 3 15
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