This checklist is suitable for mainstream golf cart models on the market. Tools to prepare before installation: Insulated gloves, torque wrench, Phillips screwdriver, multimeter, cable ties.
I. Pre-Installation Preparation
- Turn off the vehicle’s main power supply, pull out the key, and ensure the vehicle is in a powered-off and stationary state (leave it stationary for more than 10 minutes to discharge residual electricity).
- Verify the completeness of the upgrade kit accessories: Lithium battery pack, conversion wiring harness, CAN LCD instrument, 25A CAN charger, charging port, DC-DC converter, dedicated mounting bracket, US-standard charging cable.
- Wear insulated gloves and use a multimeter to test the positive and negative terminals of the original lead-acid battery to confirm no residual voltage.
II. Remove the Original Lead-Acid Battery and Auxiliary Components
- Disconnect the negative terminal (black) and positive terminal (red) of the lead-acid battery pack in sequence. Note: Disconnect the negative terminal first to prevent short circuits.
- Remove the pressure plate and bolts fixing the battery, take out all lead-acid batteries, and clean dust and corrosion in the battery compartment.
- Remove the charging port and wiring harness of the original lead-acid charger, and keep the original main wiring harness interface for later use.
III. Install the Lithium Battery Pack and Dedicated Bracket
- Fix the dedicated mounting bracket from the kit in the battery compartment, and tighten it with a torque wrench according to the instructions (torque value refers to the kit manual, usually 8-10N·m).
- Place the lithium battery pack stably into the bracket, adjust the position to ensure no looseness or deviation between the battery and the bracket, and lock the fixing bolts.
- Check the space in the battery compartment to ensure the distance between the lithium battery pack and surrounding components (such as the controller, frame) is ≥5mm to avoid friction and scraping.
IV. Wiring Connection and Component Installation
- DC-DC Converter Installation: Fix the converter in a well-ventilated position on the frame. Connect the input terminal to the positive and negative poles of the lithium battery, and the output terminal to the original 12V low-voltage system (for lights, horns and other equipment). Organize the wiring harness with cable ties.
- Conversion Wiring Harness Connection: Connect one end of the conversion wiring harness from the kit to the positive and negative poles of the lithium battery, and the other end to the original main wiring harness interface. Ensure the plug buckle is locked and there is no looseness.
- Charging Port Replacement: Remove the original charging port, install the matching charging port from the kit, and connect the charger wiring harness to ensure correct connection of positive and negative poles.
- CAN LCD Instrument Installation: Replace the original instrument, connect the CAN bus wiring harness to the CAN interface of the lithium battery pack, and ensure communication between the instrument and the battery.
V. System Debugging and Function Testing
- Turn on the vehicle’s main power supply, insert the key to start, and observe the LCD instrument display: Confirm that data such as voltage, power, and temperature are normal.
- Use a multimeter to test the output voltage of the DC-DC converter to confirm stable power supply of the 12V low-voltage system.
- Test Vehicle Functions: Start the vehicle, check if forward/reverse gears, lights, and horns work normally; conduct a short test drive to feel if the power output is smooth.
- Connect the 25A CAN charger and test the charging function: Confirm that the charger indicator light displays normally and the instrument shows the charging progress.
VI. Final Work
- Organize all wiring harnesses with cable ties to avoid winding around wheels or moving components, and ensure neat wiring.
- Recheck all terminals to confirm they are tightened without looseness. Cover the battery compartment cover and lock it.
- Keep the kit manual and lithium battery warranty card, record the installation date, and complete the installation.
VII. Notes
- Short circuit between positive and negative poles is prohibited throughout the process. Strictly follow the principle of “connect positive pole first, then negative pole” when wiring (reverse when removing).
- The lithium battery pack should avoid direct sunlight and severe collision. Use the matching CAN charger for charging; do not mix with lead-acid chargers.
- Charge fully for 12 hours for the first time to activate the maximum battery capacity.
