Club Car 1996 DS Golf Car Gasoline, Service Manual

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Page 7-1
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SECTION 7 - WHEEL BRAKE ASSEMBLIES
All 1995 and 1996 model DS Golf Cars, both gasoline and electric, are equipped with self-adjusting,
mechanically expanding shoe drum brakes on each rear wheel.
• ONLY TRAINED MECHANICS SHOULD REPAIR OR SERVICE THIS VEHICLE. ANYONE DOING
EVEN SIMPLE REPAIRS OR SERVICE SHOULD HAVE KNOWLEDGE AND EXPERIENCE IN
GENERAL 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.
• SOME BRAKE SHOES CONTAIN ASBESTOS FIBER, AND ASBESTOS DUST IS CREATED
WHEN THESE BRAKE MECHANISMS ARE HANDLED. WEAR APPROVED EYE AND RESPIRA-
TORY PROTECTION WHEN DISASSEMBLING AND CLEANING BRAKE MECHANISMS. INHALA-
TION OF ASBESTOS COULD RESULT IN SEVERE PERSONAL INJURY OR DEATH. DO NOT
USE COMPRESSED AIR OR AEROSOL SPRAYS TO CLEAN THE BRAKE MECHANISM. CLEAN
BRAKE MECHANISMS USING THE NEGATIVE PRESSURE ENCLOSURE/HEPA VACUUM SYS-
TEM OR LOW PRESSURE/WET CLEANING METHOD PER OSHA/29 CFR - 1910.1001.
• 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.
• MOVING PARTS! - DO NOT ATTEMPT TO SERVICE THE VEHICLE WHILE IT IS RUNNING.
• LIFT ONLY ONE END OF A VEHICLE AT A TIME. BEFORE LIFTING, LOCK THE BRAKES AND
CHOCK THE WHEELS THAT REMAIN ON THE FLOOR. USE A SUITABLE LIFTING DEVICE
(CHAIN HOIST OR HYDRAULIC FLOOR JACK) WITH 1000 LBS. (454 KG.) MINIMUM LIFTING
CAPACITY. DO NOT USE LIFTING DEVICE TO HOLD VEHICLE IN RAISED POSITION. ALWAYS
USE APPROVED JACKSTANDS OF PROPER WEIGHT CAPACITY TO SUPPORT THE VEHICLE.
• ALWAYS USE INSULATED TOOLS WHEN WORKING NEAR BATTERIES OR ELECTRICAL CON-
NECTIONS.
GASOLINE VEHICLES ONLY:
• TO AVOID UNINTENTIONAL STARTING OF THE VEHICLE; ALWAYS, BEFORE SERVICING:
- DISCONNECT BATTERY CABLES, NEGATIVE (-) FIRST.
- DISCONNECT THE SPARK PLUG WIRE FROM THE SPARK PLUG.
• FRAME GROUND - DO NOT ALLOW WRENCH OR OTHER METAL OBJECTS TO CONTACT
FRAME WHEN DISCONNECTING BATTERY CABLES OR OTHER ELECTRIC WIRING. NEVER
ALLOW A POSITIVE WIRE TO TOUCH THE VEHICLE FRAME, ENGINE, INNER FRAME, OR
OTHER METAL COMPONENT.
ELECTRIC VEHICLES ONLY:
• TO AVOID UNINTENTIONAL STARTING OF THE VEHICLE, DISCONNECT BATTERIES AS
SHOWN IN FIGURE 22-5 AND FIGURE 22-6, PAGE 22-5. THEN DISCHARGE THE CONTROLLER
ON POWERDRIVE SYSTEM 48 VEHICLES 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