Curtis 1268 User manual

Curtis 1206-HB to
1268 Conversion
Installation Instructions
62-EZHB-AO WORK INSTRUCTIONS REV. 02
9/14/2018

Before you start disconnect the 4 wires attached to the
(Positive) + side of the battery.
Contents: 500ACurtis controller, adapter harness, walk-away harness,
hardware kit.
A. Removing the original controller from the cart:
1. Remove the four - 10mm bolts holding the
environmental cover over the original controller
and remove cover.
3. Carefully unplug all connections to the factory
controller and remove the three –13mm bolts
securing the four large diameter wires. Save
these bolts they will be reused when installing the
new controller.
4. The factory controller is held in place by three
- 10mm bolts, remove these and save them for
later use, the factory controller can be removed
from the vehicle.
2. Unplug the tow/run switch wiring harness from
the environmental cover and set the cover to the
side, the tow/run switch will be reused later.
62-EZHB-AO WORK INSTRUCTIONS REV. 02 9/14/2018

B. Mounting the new controller:
1. Using a rag and cleaner, clear any debris from
the thermal pad to maximize thermal transfer.
2. Using the original controllers mounting bolts
and holes mount the conversion plate to the
vehicle heatsink.
3. Using a small scraper or razor blade, spread
the three tubes of thermal compound (included)
evenly over the new controllers heatsink.
4. Using the four M6 bolts, washers, and lock
washers (included) securely mount the new
controller to the adapter plate previously installed.
62-EZHB-AO WORK INSTRUCTIONS REV. 02 9/14/2018

C. Wiring the new controller:
1. Using the three 13mm bolts retained when the
original controller was removed, securely fasten
the four large diameter wires to the new
controller.
C from motor and CB+ from solenoid.
A1 from motor
CB- from battery
2. The new controller uses ring terminals instead
of faston connectors for the field connections.
Using a wire crimper and the two ring terminals
(included) cut and re-crimp the black and white
10awg wires coming from the motor.
3. Using the supplied M6 bolts, washers, and
lock washers secure the field terminals to the
new controller. The white cable gets
connected to the F1 connection the black
cable to the F2 connection.
4. Insert the conversion harness into the new
controllers 6 and 24 pin connectors.
5. Connect the 16 pin conversion harness
plug and 16 pin original wire harness plug.
62-EZHB-AO WORK INSTRUCTIONS REV. 02 9/14/2018

6. Insert the 4 pin original wire harness plug
into the new controller.
7. Remove the solenoid environmental
protection cover.
8. We will be using an open hole on the
solenoid cover mounting tab to fasten the
walk-away relay and protection fuse.
9. Using the supplied M5x20mm bolt,
washers, lock washer, and nut attach the
walk-away relay and fuse to the solenoid
cover mounting tab as shown.
10. Remove the pre-charge resistor and
connect the yellow wire from the walk-away
relay to the SOL- terminal and the red wire
from the fuse to the SOL terminal as shown.
Yellow
Red
62-EZHB-AO WORK INSTRUCTIONS REV. 02 9/14/2018

11. Plug the two wire- four pin walk-away
harness connector to the two wire- four pin
conversion harness connector then re-install
solenoid cover using original hardware.
12. Remove the tow/run switch from the
original controllers environmental cover.
13. Re-install the tow/run switch in the new
mount provided using the original hardware.
14. Mount the new tow/run switch mounting
plate using an open hole in the vehicle frame
right above the new controller using the
included M6x25mm bolt, washer, lock washer,
and nut.
13. Re-connect the four pin plug of the
tow/run switch to the four pin plug on the
original vehicle wiring harness (two red wires.)
At this point the installation is complete, use
any remaining wire ties to secure wiring and
reconnect the four wires taken off the battery
in step one.
62-EZHB-AO WORK INSTRUCTIONS REV. 02 9/14/2018