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Unread 09-21-2018, 05:15 PM   #1
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Default Leaf Battery swap in 2012 Club Car Precedent

I should be starting the installation of my lipo swap this weekend.

For those interested in cost, this is what I have into the swap so far. Now I could have saved money on batteries by getting them on ebay, but I wanted a bit more warm and fuzzy on the AH capacity of the modules. I also have tools included in the cost as I never shy away from an opportunity to expand my tool collection. This can be done with cheaper tools, I just like better tools. I also have a charger port receptacle that I broke when removing it while looking at how to retrofit the marinco charger plug into that spot. Soooooo, it can be done cheaper, but it is not a budget swap no matter how you look at it.

But the fact I will never need to deal with water levels or acid, can recharge in a couple hours, increased performance from higher voltage, and have a reliable battery "fuel" gauge ........ PRICELESS!
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Unread 09-21-2018, 08:46 PM   #2
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Default Re: Leaf Battery swap in 2012 Club Car Precedent

Nice!! I also have a spreadsheet......but yours makes mine look like an amateur.....or is that an armature!
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Unread 09-22-2018, 10:41 AM   #3
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Default Re: Leaf Battery swap in 2012 Club Car Precedent

Here is the battery tub of a Leaf lithium pack in a 2016 Precedent that I recently completed. The only thing mounted on the original controller plate is the Run/Tow switch. Everything else is moved into the tub. No cutting or modifying of any factory wiring harness to reconfigure this way.

Another thing, the original CC wiring for the programming port can be reused to wire in a SPDT switch to the controller using three of these wires. Add the switch to three of the wires under the dash and pull the pins out of the 4 pin connector and reinstall into a 3 pin shell and plug it in. Ready to go. Removal tool for the pins is needed. Drawing attached was sent to me from Alltrax.

I like your spreadsheet too.
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File Type: jpg IMG_20180406_175425935.jpg (249.5 KB, 0 views)
File Type: jpg IMG_20180406_175432657 - Copy.jpg (334.2 KB, 0 views)
File Type: jpg IMG_20180406_175440939 - Copy.jpg (381.3 KB, 0 views)
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File Type: pdf Personality Switch - XCT-SPDT-CABLE.pdf (117.1 KB, 0 views)
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Unread 09-22-2018, 10:54 AM   #4
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Default Re: Leaf Battery swap in 2012 Club Car Precedent

The first picture is of the tub after all the raised portions were removed for the bottom plate. The main harness has been rerouted down to a 1.5" hole added at the bottom of the tower that the harness originally came out of.

2nd - plates installed in bottom and tunnel installed over the main harness. DC-DC converter is mounted on top of tunnel. The bucket harness to the rear taillights is routed under the tunnel as well.

3rd - Converter sitting in position on tunnel.
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File Type: jpg IMG_20180404_134858640_LL - Copy.jpg (338.9 KB, 0 views)
File Type: jpg IMG_20180404_132134156_LL - Copy.jpg (309.0 KB, 0 views)
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Unread 09-22-2018, 07:25 PM   #5
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Default Re: Leaf Battery swap in 2012 Club Car Precedent

Took the cart apart. Don’t really need to take it this far apart, but I was doing some other cleanup as well.

Not sure how I got it to hang from the ceiling, but it sure make working on it easier than blending over.

Also started replacing the 6mm threaded rods that came from ev with 5/16” rods. I would have used the 6mm, except I wanted to space one of the side plates away from the module to allow space for a bolt to attach an Anderson Power Products SB175 plug. The original rods were not long enough.

The 5/16” rods BARELY fit the modules. They had to be threaded in, they would not just slip in.
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File Type: jpg BFA4DE1F-C3B9-4081-B5FE-C3E8B352F2E8.jpg (172.0 KB, 0 views)
File Type: jpg CCF87E37-4732-4530-BC41-9B009675D61B.jpg (171.8 KB, 0 views)
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Unread 09-22-2018, 07:33 PM   #6
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Default Re: Leaf Battery swap in 2012 Club Car Precedent

OBC removed, pack layout in battery box.
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Unread 09-22-2018, 08:21 PM   #7
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Cool Re: Leaf Battery swap in 2012 Club Car Precedent

Went to the hardware store looking for a good top plate for the battery pack that will allow me to mount the BMS, balance tap fuses, main pack fuse, etc... and I could not find one I was happy with. Came back home, and was looking around for a mounting plate. Thought about using some HDPE cutting board, but remembered I had a sign.

Now, before you think I yanked a street sign down, I am a GC and on my last school I had to replace the speed limit signs with a school zone.

After taking a vote in the house, it was decided to use the 5.

Probably should have used more painter’s tape, because a piece of aluminum got stuck to the bottom of the circular saw and left a marr from the bottom of the 5 to the top.
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File Type: jpg 3C36EBB4-8223-4EE9-8B9A-3A457213DB06.jpg (183.4 KB, 0 views)
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Unread 09-22-2018, 09:53 PM   #8
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Default Re: Leaf Battery swap in 2012 Club Car Precedent

Quote:
Originally Posted by ag4ever View Post

After taking a vote in the house, it was decided to use the 5.
I would have voted for the 5 as well!!! When I was a kid.....like 17YO, me and two buddies went up to the highway.....a good mile away....and we stole a giant 6x6 sign that said "SINGLE LANE AHEAD".

I hung that sign in my Dad's detached garage. It stayed there for at least 5 or 6 years. Don't ask what my Dad said when he saw it.

I like it!!!
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Unread 09-22-2018, 10:21 PM   #9
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Default Re: Leaf Battery swap in 2012 Club Car Precedent

Time to bypass the obc signal to the controller.

Luckily, I recently replaced the gauges in my boat. The connectors were all deutsch. So, I took that opportunity to buy some more tools (can never have too many tools).

I also had some spare barrel connectors, and filler pins. All I needed was the 6 conductor housing and lock.

Strip, crimp, insert till it clicks, slide in the lock, insert dummy pins. Done.

If you need to take one apart, the proper tool is the DT-RT1. It has a hook on one end to pull out the pin lock, and flat blade on the other end to release the plastic retainer in the housing.
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Unread 09-22-2018, 10:25 PM   #10
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Default Re: Leaf Battery swap in 2012 Club Car Precedent

More obc bypass photos
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