1. Introduction
This instruction manual provides essential information for the proper installation, operation, and maintenance of your D&D Motor Systems Club Car DS Series Golf Cart Motor, model 170-004-0002A. This motor is designed for 36V or 48V Club Car DS series electric golf carts, offering increased torque and speed compared to stock motors. Please read this manual thoroughly before installation and use to ensure safe and optimal performance.
Image 1.1: D&D Motor Systems Club Car DS Series Golf Cart Motor (Model 170-004-0002A).
2. Important Safety Information
WARNING: STOCK COMPONENT RESTRICTION
This product is intended for use in applications where the vehicle is stock only. This means the golf cart should not have modifications such as, but not limited to, a lift kit, larger tires, backseat, backbed, or trailer hitch. Additionally, the vehicle should only be operated in a flat environment and at speeds of 14 MPH or less.
DISCLAIMER: PRODUCT LIABILITY
No product liability can be provided or assumed until D&D Motor Systems has all the necessary information regarding your vehicle's setup, application, and performance requirements. It is crucial to contact D&D Motor Systems Inc. at 315-701-0635 to confirm compatibility and setup approval before installation and use.
3. Product Features
The D&D Motor Systems 170-004-0002A motor offers several advanced features:
- High Performance: Provides 15 MPH speed at 48V and 40% more torque compared to a stock golf cart motor.
- Compatibility: Designed for 36V/48V Club Car DS Series golf carts with a stock 10-tooth differential spline.
- Enhanced Durability: Features increased copper and steel content for higher thermal capabilities.
- Advanced Shaft Treatment: Special shaft heat treating reduces motor noise and shaft wear.
- Corrosion Resistance: Equipped with a durable and corrosion-resistant powder coating.
- American Made: Manufactured by D&D Motor Systems Inc. in the USA.
Image 3.1: Internal view highlighting special shaft heat treating for reduced noise and wear.
Image 3.2: Motor exterior showing Class H Thermal Rating and durable powder coating.
4. Compatibility and Golf Cart Identification
It is critical to correctly identify your golf cart type (Series or Regen) and model to ensure compatibility with this motor. This motor is specifically designed for Series electric golf carts.
4.1. Identifying Series vs. Regen Golf Carts
Use the following questions to determine your golf cart type:
- Does your cart have a Run/Tow Switch?
If YES, it is likely a REGEN cart. - Does your existing motor have a speed sensor wire?
If YES, it is likely a REGEN cart.
If you answer NO to BOTH questions, your cart is a SERIES vehicle, and this motor is compatible. If you answer a combination of YES and NO, or are unsure, please contact D&D Motor Systems for assistance.
Image 4.1: Visual guide for identifying Series or Regen golf carts.
4.2. Identifying Series Golf Cart Make & Model (Club Car)
For Club Car Series models, you can typically find the serial number on the passenger side of the glove box, from 1981 to present. The first two numerical characters indicate the last two digits of the year of manufacture.
Image 4.2: Guide for identifying Series Club Car models.
This motor is a direct replacement for OEM# D395.
4.3. D&D Motor Product Line Overview
The following table provides an overview of D&D Motor Systems' product line, including Series Motors. This motor (170-004-0002A) is listed under Club Car Series motors.
Image 4.3: D&D Motor Product Line table.
5. Installation Guide
Motor installation should ideally be performed by a qualified technician. Always disconnect the battery pack before beginning any work on your golf cart's electrical system.
5.1. General Installation Steps (Consult a professional for detailed instructions)
- Safety First: Ensure the golf cart is turned off, in neutral, and the parking brake is engaged. Disconnect the main battery pack.
- Access Motor: Locate and access the existing motor. This may involve removing covers or other components.
- Disconnect Wiring: Carefully label and disconnect all electrical wires from the old motor.
- Remove Old Motor: Unbolt and remove the old motor from the differential.
- Install New Motor: Mount the new D&D Motor Systems 170-004-0002A motor to the differential.
- Connect Wiring: Reconnect the electrical wires to the new motor, ensuring correct polarity and secure connections. This motor typically involves 4 wires for series carts.
- Secure Components: Reinstall any covers or components removed during the process.
- Reconnect Battery: Reconnect the main battery pack.
- Test Functionality: Test the golf cart's operation in a safe, open area.
Note on Mounting Bolts:
Some users have reported that the OEM mounting bolts may not be compatible with the new motor due to thread differences (fine vs. coarse). You may need to acquire new mounting bolts that match the threading of the D&D motor.
Before installation, D&D Motor Systems recommends contacting them to ensure your specific golf cart setup is approved for this motor. Call 315-701-0635.
6. Operation
This motor is designed to operate with either a 36V or 48V electrical system. Ensure your golf cart's controller and battery system are compatible with the motor's performance characteristics. The motor provides increased speed and torque, which may require adjustments to your driving habits, especially on varied terrain.
Always operate your golf cart responsibly and adhere to all local regulations and safety guidelines.
7. Maintenance
Proper maintenance ensures the longevity and optimal performance of your D&D motor.
- Regular Inspection: Periodically inspect the motor for any signs of damage, loose connections, or excessive dirt buildup.
- Cleanliness: Keep the motor clean and free from debris, especially around cooling vents (if present).
- Connection Checks: Ensure all electrical connections are tight and free from corrosion. Loose connections can lead to overheating and performance issues.
- Brush Inspection (if applicable): If your motor is a brushed type, consult a technician for periodic brush inspection and replacement as needed.
- Avoid Overloading: Do not consistently operate the golf cart beyond its recommended load capacity, as this can stress the motor.
8. Troubleshooting
If you experience issues with your motor, consider the following basic troubleshooting steps. For complex problems, contact D&D Motor Systems technical support.
| Symptom | Possible Cause | Action |
|---|---|---|
| Motor not running or weak performance | Low battery charge, loose electrical connections, faulty controller, motor issue | Check battery charge, inspect all wiring connections, consult a technician for controller/motor diagnosis. |
| Motor overheating | Overloading, prolonged uphill driving, restricted airflow, faulty controller | Reduce load, allow motor to cool, ensure proper ventilation, consult technician. |
| Unusual noises from motor | Loose components, internal wear, foreign object | Immediately cease operation and have the motor inspected by a qualified technician. |
9. Specifications
| Specification | Detail |
|---|---|
| Model Number | 170-004-0002A |
| Brand | D&D Motor Systems |
| Voltage | 36 Volts, 48 Volts |
| Horsepower | 10.2 Horsepower |
| Material | Alloy Steel |
| Item Weight | 62 Pounds |
| Package Dimensions | 12.63 x 9.88 x 9.88 inches |
| Replaces OEM # | D395, 5BC48JB1134, GN1-4001 |
10. Warranty and Support
10.1. Warranty Information
A 1-year warranty is provided only if D&D Motor Systems has all the information regarding your vehicle setup, application, and performance requirements, and approves your setup. It is essential to contact D&D Motor Systems Inc. to discuss your specific application.
10.2. Technical Support
D&D Motor Systems is committed to ensuring you have the correct motor for your golf cart. For technical support, setup approval, or any questions, please contact:
D&D Motor Systems Inc.
Phone: 315-701-0635
