Deere and ISG Electronic Systems JDGT-0001 Skylinks Head Unit and Skylinks Power Supply User Manual John Deere Golf Technologies

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Document ID	137256
Application ID	24FsHEyOOzn9rs4A2wVf4A==
Document Description	corrected installation manual
Short Term Confidential	No
Permanent Confidential	No
Supercede	No
Document Type	User Manual
Display Format	Adobe Acrobat PDF - pdf
Filesize	55.55kB (694378 bits)
Date Submitted	2001-02-20 00:00:00
Date Available	2001-03-05 00:00:00
Creation Date	2001-02-13 14:20:17
Producing Software	Acrobat Distiller 4.05 for Windows
Document Lastmod	2001-02-13 14:20:56
Document Title	John Deere Golf Technologies
Document Creator	Microsoft Word 9.0
Document Author:	Gary Searl

John Deere Golf Technologies
Installation Manual
Generation 4
John Deere Golf Technologies
3159 Royal Drive, Suite 320
Alpharetta, GA 30022
1-877-298-8515
Dec 04, 2000
Club Car Post 2000 – Table of Contents
Overview ................................................................
................................................................................................
.......................................................................
....................................... 2
Parts List ................................................................
................................................................................................
.......................................................................
....................................... 3
Assembly Part Numbers ....................................................................................................................................................... 3
Service Part Numbers ........................................................................................................................................................... 5
Parts Included in Bill of Material......................................................................................................................................... 6
Tools and Equipment ............................................................................................................................................................ 9
Basic System Layout ................................................................
.................................................................................
................................................. 10
Installation Instructions
Instructions................................
................................................................
..............................................................................
.............................................. 11
Overview of Club Car Post 2000 UHF Antenna Bracket Installation ................................................................. 11
Club Car UHF Post 2000 Bracket Installation ............................................................................................................... 13
Overview of Club Car Post 2000 GPS Antenna Bracket Installation ............................................................................. 17
Club Car Post 2000 GPS Bracket Installation ................................................................................................................ 18
Overview of Club Car Post 2000 Power Harness Installation ......................................................................................... 21
Club Car Power Harness Installation ............................................................................................................................... 24
Overview of Club Car Post 2000 Display Unit Bracket Installation ............................................................................... 28
Club Car Display Unit Bracket Installation .................................................................................................................... 29
Overview of Generic Display Unit Installation ................................................................................................................. 32
Club Car Display Unit Installation ................................................................................................................................... 33
Trouble Shooting ................................................................
.........................................................................................
......................................................... 35
Live With Safety
Please before returning cart to customer, make sure cart is
Functioning properly, especially the safety systems.
Install all safety guards and shields.
Overview
General System
SkyLinks is a golf management / information system. It provides valuable information to the
golfer and the course manager through such technologies as satellite navigation and digital
radio communications.
The main components of SkyLinks are the computer display units on each golf cart, a central
computer server in the clubhouse, workstation computer(s), and a communications system to
tie it all together.
Golf cart computers
The golf cart computer performs the following functions:
Vehicle tracking with GPS (Global Positioning System)
Data feed to/from the clubhouse
o Advertising images
o Text messages from the clubhouse
o Display tailored to the golfer to display:
! Course map display
! Accurate yardage information
! Pro's tips
Parts List
Assembly Part Numbers
Part numbers are assigned by Phoenix International, and are subject to change without notice
Item
Part Number
Description
HEAD UNIT ASSEMBLY
JDGT-0001
Display Unit
POWER SUPPLY
JDGT-0002
Power Supply
BKT, PWR SUPPLY – CLUBCAR
800-0267
Assy with Power Supply
CLAMP, DISPLAY – CLUB CAR
800-0255
Assy with P/N 800-0267 and P/N 950-0093
CBL ASSY, CLUBCAR ELECTRIC
440-0600
Power Harness Assembly
CBL ASSY, CLUBCAR GAS
440-0660
Power Harness Assembly
JDGT HDW KIT
PHMS, PHIL, 10-32 X .750
JDGT-0004
Bulk Item Hardware Kit
812-0067
Screw to secure P/N 800-0255
PHMS, PHIL, 10-24 X 1.50
812-0068
Screw to secure P/N 800-0246
PHMS, PHIL, ¼-20 X .500
812-0075
Secures Head Unit
HHMS, CAP ¼-20 X 2.75”
816-0006
Secures Power Supply to bracket
LOCKWASHER, INT, 1/4?” ZNC
832-0019
Assy with P/N 812-0075
WSHR, FLAT #10 SS MS15795
838-0033
Assy with P/N 812-0068
SPCR, CLUBCAR ANTENNA BKT
840-0111
Assy with P/N 800-0246
CABLE TIE, 7.4” STANDARD
850-0005
Secures UHF and GPS Antenna Cables to Cart
CARTON 10 x 6 x 4
900-0053
Box to Hold Bulk Items
POLY BAG, ZIP-LOCK 4 X 6
901-0016
Packaging for shipping
BAG, 10 X 13 2 MIL
901-0022
Packaging for shipping
JDGT HDW KIT
JDGT-0013
Bulk Item Hardware Kit
PHMS, PHIL, 10-32 X .750
812-0067
Screw to secure P/N 800-0255
PHMS, PHIL, 10-24 X 1.75
812-0086
Screw to secure P/N 800-0246
PHMS, PHIL, ¼-20 X .500
812-0075
Secures Head Unit
PHMS, PHIL, 10-24 X .312
812-0087
Secures P/N 800-0290 and P/N 800-0292
HHMS, CAP ¼-20 X 2.75”
816-0006
Secures Power Supply to bracket
LOCKWASHER, INT, 1/4?” ZNC
832-0019
Assy with P/N 812-0075
WSHR, FLAT #10 SS MS15795
838-0033
Assy with P/N 812-0068
SPCR, CLUBCAR ANTENNA BKT
840-0111
Assy with P/N 800-0246
CABLE TIE, 7.4” STANDARD
850-0005
Secures UHF and GPS Antenna Cables to Cart
CARTON 10 x 6 x 4
900-0053
Box to Hold Bulk Items
POLY BAG, ZIP-LOCK 4 X 6
901-0016
Packaging for shipping
BAG, 10 X 13 2 MIL
901-0022
Packaging for shipping
JDGT BKT/ANT KIT-CLUB GAS
JDGT-0011
GEN 4 Club Car Gas Pre 2000 roof
CBL ASSY, CLUBCAR GAS
440-0660
Power Harness Assembly
BKT ASSY, CLUB CAR DSPLY
950-0093
Bracket for Display Unit
UHF ANT/BKT ASSY CLUBCAR
950-0094
UHF RADIO BRACKET ASSEMBLY PRE 2000
CLAMP, DISPLAY – CLUB CAR
CRTN, 22 5/16 X 18 3/16 X
PARTITION, 35 CELL
800-0255
900-0001
900-0006
Assy with P/N 800-0267 and P/N 950-0093
Packaging for shipping
Packaging for shipping
BUBBLE WRAP, ANT-STATIC
903-0001
BKT ASSY, CLUB CAR DSPLY
950-0093
Bracket for Display Unit
Cover, Support – Club Car
800-0250
Cover Support Display
Support, Center –Club Car
800-0251
Center Support Display
BKT, MTG – Club Car
800-0852
Mounting Bracket Display
Plate, MTG – Color DSPLY
800-0853
Mounting Plate Display
PHMS, PHIL, 10-32 x .375
812-0066
Hex Nut, 1/4 –20 Jam 18-8
822-0025
Secures P/N 845-0007
Bumper, 1” OD ¼ -20 x .50
845-0007
Attaches to Center Support
Grommet, Neoprene ID=5/16
845-0007
Grommet, Neoprene ID=1/2
881-0009
Antenna, GPS 8ft SMA MAG
496-0002
GPS Antenna
BKT, Antenna – Club Car
800-0246
Bracket for Antenna
Pad, Antenna MTG – PSC
852-0006
Adhesive for Antenna
BKT, Ant GPS Club Car 2000
800-0291
Bracket for GPS Antenna Post 2000
UHF ANT/BKT ASSY CLUB 2K
950-0106
UHF BRACKET ASSEMBLY POST 2000
Antenna, UHF Maxrad
496-0006
UHF Antenna
BKT, Ant UHF Club 2k
800-0290
Top Piece of Post 2000 UHF Antenna
PHMS, PHIL 10-24 X 1.75
812-0086
Secures P/N 800-0290 and P/N 800-0292
BKT, Ant-Bottom Club 2000
800-0292
Bottom Piece of Post 200 UHF antenna
Service Part Numbers
Service part numbers may be different from Bill of Material part numbers.
Part numbers are assigned by Phoenix International, and are subject to change without notice.
Item
Description
Part Number
ANTENNA, GPS 8ft SMA MAG
496-0002
GPS antenna
ANTENNA, UHF Maxrad
496-0006
UHF Antenna
CBL ASSY, CLUBCAR ELECTRIC
440-0600
Power Harness Cable
CBL ASSY, CLUBCAR GAS
440-0660
Power Harness Cable
DISPLAY UNIT
JDT-0001
Display
FUSE 3A, AUTO BLADE VI0
861-0054
3-amp fuse
GPS ANT/BKT ASSY CLUB CAR
800-0291
GPS bracket for Club Car Post 2000
HDWE PKG, CLUB CAR- COLOR
920-0017
Head Unit Bracket Assembly
PAD, ANTENNA MTG – PSC
852-0006
Circular adhesive for GPS Ant
POWER SUPPLY
UHF ANT/BKT ASSY CLUBCAR
JDGT-0002
Wedge Box
496-006
UHF bracket for Club Car Post 2000
Parts Included in Bill of Material
There are different parts numbers for the Power Harness, GPS Antenna Bracket, and UHF Antenna Bracket
based on the specific cart model and year.
Club Car Sub-Assemblies
CBL ASSY, CLUBCAR ELECTRIC P/N 440-0600 AND POWER SUPPLY
1. Power Harness Assembly
(P/N 440-0660)
2. Power Supply Bracket
(P/N 800-0267)
3. Clamp and screw
(P/N 800-0255 and P/N 812-0067)
4. Bolt
(P/N 816-0006)
5. Power Supply
(P/N JDGT-0002)
CBL ASSY, CLUBCAR GAS P/N 440-0660 AND POWER SUPPLY
1. Power Harness Assembly
(P/N 440-0660)
2. Power Supply Bracket
(P/N 800-0267)
3. Clamp and screw
(P/N 800-0255 and P/N 812-0067)
4. Bolt
(P/N 816-0006)
5. Power Supply
(P/N JDGT-0002)
GPS ANT/BKT ASSY CLUBCAR P/N 950-0095 (Post 2000)
1. GPS Bracket
(P/N 800-0291)
2. GPS Antenna
(P/N 496-0002)
UHF ANT/BKT ASSY CLUB CAR P/N 950-0094 (Post 2000)
1. Antenna bracket bottom
(P/N 800-0292)
2. Antenna bracket top
(P/N 800-0290)
3. Antenna
(P/N 496-0006)
4. Screws to attach brackets
(P/N 812-0086)
5. Sheathing
(P/N 840-0111)
6. Washer
(P/N 838-0033)
7. Mounting screws
(P/N 812-0068)
HDWE PKG, CLUB CAR- COLOR P/N 950-0093
1.
2.
3.
4.
5.
6.
7.
8.
Bumper
Hex Nut
Center Support
Clamp
Display Unit Plate
Main Bracket
Screws
Support Cover
(P/N 845-0007)
(P/N 822-0025)
(P/N 800-0251)
(P/N 800-0255)
(P/N 800-0853)
(P/N 800-0852)
(P/N 812-0066)
(P/N 800-0251)
Tools and Equipment
Not Supplied With Kit
Club Car Tools and Equipment
Required-Under Review
Crescent Wrench
Electric Screwdriver/Drill
Phillips Head Bit
Phillips Screwdriver
Socket Adapter
Wire Cutters
½ -9/16” Socket
7/16” Socket
7/16” Wrench
½” Nut driver
3/8” Nut driver
5/16” Nut driver
Basic System Layout
Display Unit
RF Antenna
GPS Antenna
Battery
Connectors
Power Harness
Fuse Holder
Key Switch Connector
Power supply
1-GPS Antenna
2-RF Antenna
3-Display Unit
Basic Components:
1. Antennas
2. Display Unit
3. Power Supply
4. Power Harness
4-Power Harness
5-Battery Connectors
6-Fuse Holder
7-Power Supply
8-Key Switch connector
Before Installation review manual. To prevent
damage to components and cart.
10
Installation Instructions
Overview of Club Car Post 2000 UHF Antenna Bracket Installation
FCC Antenna Radiation Caution to Installers
Use of any antenna other than the one provided with this kit may expose the user to radio frequency
(RF) emission levels outside the FCC safety guidelines.
IMPORTANT NOTE: To comply with FCC RF exposure requirements, the following antenna
installation and device-operating configuration must be followed to ensure a separation distance of
20 cm between the antenna and the operators of the golf cart
Left (drivers side) and Right side of cart will be identified as someone sitting forward in cart.
Before doing any work on golf cart, make sure that the key is in the off position.
Ensure the parking brake is set.
Remove windshields if installed before beginning as per Cart Manufacture User’s Manual.
The UHF antenna cable is not attached to the Display Unit during this phase of the installation. Leave
cable assemble available for easy access for latter in the installation.
Specific UHF Antenna Bracket Installation instructions per cart type (ex. Club Car, EZ-GO, Yamaha), and
model.
11
Club Car Post 2000 UHF Antenna Bracket Installation Parts (P/N 950-0106)
1. Antenna Bracket Bottom
(P/N 800-0292)
2. Antenna Bracket Top
(P/N 800-0290)
3. Antenna
(P/N 496-0006)
4. Securing bracket screws
(P/N 812-0086)
5. Spacer
(P/N 840-0111)
6. Phillips Screws (2)
(P/N 812-0086)
7. Flat Washer (2)
(P/N 838-0033)
Club Car Post 2000 Completed UHF Bracket Installation
12
Club Car UHF Post 2000 Bracket Installation
1. Remove right side 7/16
bolts securing roof
Note: save 7/16 bolts and
nuts for de-installation.
13
2. Attach screw, washer and
plastic sheathing to bracket,
and secure
Important:
UHF bracket
needs to be isolated from
cart ground.
Note: Use Part Numbers:
840-0111 spacer
838-0033 washer
812-0086 screw
800-0292 bottom half of
bracket
3. Attach top half of
antenna bracket with
screws and lock
tight.
Note: Use Part Numbers:
800-0290 top half of bracket
812-0086 screws
14
4. Attach Antenna
cable to bracket.
Caution
The installer(s) must
follow the antenna
installation procedure set
fourth in this manual to
insure that while the
device is in operation, a
separation of at least 20
cm is maintained between
antenna and the user.
These instructions must
be followed in order to
meet the FCC RF
exposure guidelines.
These requirements can
only be met if the antenna
is installed as described
in the installation
procedure steps and
depicted in the pictures of
the antenna location and
mounting bracket
5. Attach antenna whip
to cable base.
Caution
The installer(s) must
follow the antenna
installation procedure set
fourth in this manual to
insure that while the
device is in operation, a
separation of at least 20
cm is maintained between
antenna and the user.
These instructions must
be followed in order to
meet the FCC RF
exposure guidelines.
These requirements can
only be met if the antenna
is installed as described
in the installation
procedure steps and
depicted in the pictures of
the antenna location and
mounting bracket
Note: Use Part Number:
496-0006 antenna assy.
15
6. Route UHF antenna cable
down roof support. Placing the
first tie strap at the top bend of
support, and another every 6-8
inches.
Important: Do not pull UHF
cable tight at the roof
location. Allow a gentle bend
to cart frame.
= Zip tie location
6. This completes the UHF
bracket and UHF cable
installation.
Note: Leave UHF cable
connector end unattached. It
will be connected latter in the
installation.
16
Overview of Club Car Post 2000 GPS Antenna Bracket Installation
Left (drivers side) and Right side of cart will be identified as someone sitting forward in cart.
Before doing any work to the golf cart, make sure the key is in the off position.
Ensure the parking brake is set.
Remove windshields if installed before beginning installation as per Cart Manufacture User’s Manual.
The GPS antenna cable is not attached to the Display Unit during this phase of the installation. Leave
cable assemble available for easy access for latter in the installation.
Specific GPS Antenna Bracket Installation instructions per cart type ex. (Club Car, EZ-GO, Yamaha) and Model
type.
Club Car Post 2000 GPS Antenna Bracket Installation Parts
1. GPS Antenna
(P/N 800-0291)
2. GPS Bracket
(P/N 496-0002)
Club Car Completed Post 2000 GPS Bracket Installation
17
Club Car Post 2000 GPS Bracket Installation
1. Remove front
7/16 bolt with
locking nut on left
side.
18
2. Mount GPS antenna
bracket with 7/16 bolt
that was removed in step
1, and reattach.
Note: Use Part Number:
496-0002 GPS Bracket
3. Mount GPS antenna
on bracket. Antenna
attaches magnetically.
Note: Use Part Number:
800-0291 GPS Antenna
19
3. Route GPS antenna cable
down roof support. Placing
the first tie strap at the top
bend of support, and another
every 6-8 inches.
Important: Do not pull
GPS cable tight at the roof
location. Allow a gentle
bend to cart frame.
= Zip tie location
4. This completes the GPS
bracket and GPS cable
installation.
Note: Leave GPS cable
connector end unattached.
It will be connected latter in
the installation.
20
Overview of Club Car Post 2000 Power Harness Installation
•
•
•
•
•
•
Make sure key switch is in the off position.
Use caution when working around the batteries. Battery acid may exist around the terminal area.
Verify the positive lead and ground of cart.
When routing the Power Harness cable make sure the cable does not interfere with cart operation.
The cable should be isolated of working parts of the cart.
Two installers are required to remove seat to avoid back injuries.
Parts Required for Assembly of Power Supply Bracket and Mounting Power Supply
1. Power Harness
Electric (P/N 440-0600)
Gas (P/N 440-0660)
2. Power Supply Bracket
(P/N 800-0267)
3. Clamp
(P/N 800-0255)
4. Phillip Head Screw
(P/N 812-0067)
5. Bolt (4)
(P/N 816-0006)
6. Power Supply
(P/N JDGT-0002)
Club Car Power Harness Installation Parts
21
Assembly of Power Supply Bracket and Mounting Power Supply
1. Insert screw into
hole on flat side of
Power Supply
Bracket
2. Start screw into
clamp
Note: Use Part Numbers:
P/N 800-0255 clamp
P/N 812-0067 screw
Note: Notch of clamp
should be to the inside
towards power supply
bracket.
3. Mount Power
Supply onto bracket
using four bolts.
Note: Power Supply
connector should be
facing towards beveled
end of power supply
bracket.
Note: Use Part Numbers:
P/N 816-0006 bolts
P/N JDGT-0002 Power
Supply
P/N 440-0600 electrical
P/N 440-0660 gas
P/N 800-0267 bracket
22
Club Car Completed Power Harness Installation
Power Supply Location
23
Club Car Power Harness Installation
Note: Two Persons Should
be used to Remove Seat.
1. Remove Seat
2. Mount Power Supply
Bracket to cart.
Location is left side
3. Tighten screw for
Wedge
4. Remove Dash
Note: Use Steps 5 through
18
5. Remove screw caps
on the side of
dashboard, and save
6. Loosen screws
securing dashboard
7. Pop off top of
dashboard by running
screwdriver along the
top of dash and below
frame of cart
8. Bend top right corner
of dash inward to get
key switch assembly
out of dash
Note: DO NOT LET KEY
SWITCH COME IN CONTACT
WITH FRAME OF CART. IT
WILL BLOW THE FUSE TO
THE CART.
A. Remove cap
B. Loosen screw
E. Insert screwdriver here to remove dash.
F. Run screwdriver along black line
9. Run screwdriver along
bottom side of
dashboard to finish
removing
C. Remove cap
D. Loosen screw
10. Clip a ½” x ½” notch in
the lower right corner
of the dashboard.
Note: This is to allow
enough clearance for the
power cable to be ran into
the bracket and attach to
the head unit.
24
11. Route Power cable
along frame of cart.
Secure with tie straps.
In predrilled holes.
12. Pull about 1’ 6” of
cable out to be ran for
the Display Unit.
Cable Length
Installation Tip:
Run power cable to corner
of compartment.
13. Insert bottom of
dashboard back into
place
Note: BE CAREFUL NOT TO
ALLOW THE KEYSWITCH
TO COME IN CONTACT
WITH THE CART FRAME.
14. Bend right corner
inward to allow key
switch room to be
inserted
15. Place left corner in
place
16. Push top part of dash
into place
Bend corner inward to get key switch past frame
17. Tighten screws
18. Replace caps
19. Attach Black wire to
cart ground and
secure with 5/16” lock
washer 5/16” nut.
Cart Ground Connection
20. Route Red and Blue
wire. Securing with tie
straps.
Note: The cable should be
isolated of working parts of
the cart.
25
21. Remove Electrical
Component Box
Cover with 3/8” nut
driver.
22. Remove Nut securing
cart’s blue wire
23. Install blue wire to
electrical system for
key switch.
24. Reinstall nut securing
both blue key switch
wires.
Blue wire for key switch
connection.
25. Remove Nut securing
red battery lead on
solenoid with ½” nut
driver.
26. Attach red wire to
solenoid post.
27. Reinstall nut securing
red wire and red
battery lead with nut.
Nut securing red wire on solenoid
28. Tighten with ½” nut
driver.
26
29. Secure fuse holder to cart
with tie strap.
Note: Make Sure Fuse
Holder is in a Vertical
Position with Leads
Facing Toward the
Ground, and the Fuse
Holder is Accessible
30. Replace the Seat
27
Overview of Club Car Post 2000 Display Unit Bracket Installation
•
•
•
•
•
Left (drivers side) and Right side of cart will be identified as someone sitting forward in cart.
Make sure key switch is in the off position.
Ensure the parking brake is set.
When routing the Power Harness cable make sure the cable does not interfere with cart operation.
The cable should be isolated of working parts of the cart.
Specific Display Unit Bracket Installation instructions per cart type ex. (Club Car, EZ-GO, Yamaha)
Club Car Display Unit Bracket Installation Parts
1. Display Unit Bracket
Club Car Completed Display Unit Bracket Installation
28
Club Car Display Unit Bracket Installation
1. Install Mounting
Bracket on left
side of cart.
Note: Place
bracket as close to
dash as possible.
2. Push bracket up
until ridge of
bracket inserts
under lip of cart.
Also ensure the
lower wedge
pieces are
positioned
correctly.
Note: Wedge
pieces should be
aligned so the
notch sits properly
to cart edge.
29
3. Install
centerpiece to
bracket. Secure
with four
screws.
30
4. Run Power
Harness cable
behind
mounting
bracket and into
hole in center
piece of display
bracket.
5. Route GPS and
UHF cables
through the
center hole of
center support.
31
Overview of Generic Display Unit Installation
•
•
•
•
•
•
Left (drivers side)and Right side of cart will be identified as someone sitting forward in cart.
Make sure key switch is in the off position.
Ensure the parking brake is set.
When routing the Power Harness cable make sure the cable does not interfere with cart operation.
The cable should be isolated of working parts of the cart.
Use caution when installing the UHF and GPS connectors to the Display Unit.
Specific Display Unit Bracket Installation instructions per cart type ex. (Club Car, EZ-GO, Yamaha)
Club Car Display Unit Installation Parts
1. Display Unit
P/N JDGT-0001
2. Screws (4)
P/N 812-0075
Club Car Display Unit Installation
32
Club Car Display Unit Installation
1. Connect Power
Harness connector to
Display Unit
2. Attach UHF Connector
to Display Unit
33
3. Attach GPS Connector
to Display Unit
4. Secure Display Unit to
Display Bracket using
hex head screws.
34
Trouble Shooting
35
36
37
38
39

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Modify Date                     : 2001:02:13 14:20:56-05:00
Create Date                     : 2001:02:13 14:20:17-05:00
Title                           : John Deere Golf Technologies
Author                          : Gary Searl
Creator                         : Microsoft Word 9.0
Producer                        : Acrobat Distiller 4.05 for Windows
Page Count                      : 40

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