Club Car 1996 DS Golf Car Gasoline, Service Manual

Page: 525 / 544

Page 24-1
24
E
SECTION 24 - MOTOR
GENERAL INFORMATION
Club Car DS V-Glide vehicles are equipped with 36 volt DC, series wound, reversible traction motors; DS
PowerDrive System 48 vehicles are equipped with 48 volt DC, series wound, reversible traction motors; and
DS PowerDrive Plus vehicles are equipped with 48 volt DC, shunt wound, reversible traction motors. The
information in this section applies to all three motors. Motors requiring major repair should be sent to a qual-
ified motor repair shop. There are, however, many relatively easy repairs that can be made by the average
mechanic.
EXTERNAL MOTOR TESTING
Using a multimeter (Club Car Part No. 1011480) or a continuity tester (Club Car Part No. 1011273), the fol-
lowing tests can be performed without disassembling the motor.
TEST PROCEDURE 1 - CHECK FOR INTERNAL SHORT CIRCUIT
1. Disconnect the wires from all the terminals on the motor. Using a multimeter set on ohms (
Ω
), place the
black (-) probe of the multimeter on the motor housing. Scratch through the paint to insure a good con-
nection. Place the red (+) probe on the A1, A2, S1, and S2 terminals respectively (Figure 24-1, Page
24-2). The readings should be no continuity. If the readings are incorrect, the motor will need to be
removed from the vehicle and repaired by a qualified technician (See Motor Removal, Page 24-3).
• ONLY TRAINED TECHNICIANS SHOULD REPAIR OR SERVICE THIS VEHICLE. ANYONE DOING
EVEN SIMPLE REPAIRS OR SERVICE SHOULD HAVE KNOWLEDGE AND EXPERIENCE IN
GENERAL ELECTRICAL REPAIR. FOLLOW ALL PROCEDURES EXACTLY AND HEED ALL
WARNINGS STATED IN THIS MANUAL.
• ALWAYS WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION WHILE SERVICING
VEHICLE. WEAR A FULL FACE SHIELD WHEN WORKING WITH BATTERIES.
• TURN KEY SWITCH OFF, PLACE FORWARD AND REVERSE LEVER IN THE NEUTRAL POSI-
TION, AND REMOVE KEY PRIOR TO SERVICING.
• DO NOT WEAR LOOSE CLOTHING. REMOVE JEWELRY SUCH AS RINGS, WATCHES, CHAINS,
ETC. BEFORE SERVICING VEHICLE.
• ALWAYS USE INSULATED TOOLS WHEN WORKING NEAR BATTERIES OR ELECTRICAL CON-
NECTIONS.
• TO AVOID UNINTENTIONAL STARTING OF THE VEHICLE, DISCONNECT BATTERIES AS
SHOWN IN FIGURES 22-5 AND 22-6, PAGE 22-5.
• ON POWERDRIVE SYSTEM 48 VEHICLES, AFTER DISCONNECTING BATTERIES DISCHARGE
THE CONTROLLER AS FOLLOWS:
- TURN THE KEY SWITCH TO ON AND PLACE THE FORWARD AND REVERSE LEVER IN THE
REVERSE POSITION.
- SLOWLY DEPRESS THE ACCELERATOR PEDAL AND KEEP IT DEPRESSED UNTIL THE
REVERSE WARNING BUZZER CAN NO LONGER BE HEARD. WHEN THE BUZZER STOPS
SOUNDING, THE CONTROLLER IS DISCHARGED.
WARNING