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2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement

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FOREWORD

Club Car vehicles are designed and built to provide the ultimate in performance efficiency; however, proper
maintenance and repair are essential for achieving maximum service life and continued safe and reliable
operation.

This supplement provides detailed information for the maintenance and repair of V-Glide 36-Volt electric vehi-
cles and should be used in conjunction with the 2004 DS Golf Car Maintenance and Service Manual (CCI P/
N 102397601).

If you do not have a 2004 DS Golf Car Maintenance and Service Manual, you may order one from your local
Club Car representative.

This supplement, in addition to the 2004 DS Golf Car Maintenance and Service Manual, should be thoroughly
reviewed prior to servicing the vehicle. The procedures provided must be properly implemented, and the DAN-
GER, WARNING and CAUTION statements must be heeded.

This supplement was written for the trained technician who already has knowledge and skills in electrical and
mechanical repair. If the technician does not have such knowledge and skills, attempted service or repairs to
the vehicle may render the vehicle unsafe. For this reason, Club Car advises that all repairs and/or service be
performed by an authorized Club Car distributor/dealer representative or by a Club Car factory-trained tech-
nician.

It is the policy of Club Car, Inc. to assist its distributors and dealers in continually updating their service knowl-
edge and facilities so they can provide prompt and efficient service for vehicle owners. Regional technical rep-
resentatives, vehicle service seminars, periodic service bulletins, maintenance and service manuals, and
other service publications also represent Club Car’s continuing commitment to customer support.

This supplement, used in conjunction with the 2004 DS Golf Car Maintenance and Service Manual, covers all
aspects of typical vehicle service; however, unique situations do sometimes occur when servicing a vehicle.
If it appears that a service question is not answered in this supplement, you may write to us at: Club Car, Inc.,
P.O. Box 204658; Augusta, Georgia 30917-4658, USA, Attention: Technical Services, or contact a Club Car
Technical Service Representative at (706) 863-3000, ext. 3580.

This supplement does not contain maintenance and service procedures for the battery charger. Contact your
local Club Car representative for information on how to obtain the appropriate battery charger maintenance
and service manual.

Copyright © 2003 Club Car, Inc.

Club Car

and

ArmorFlex

are registered

trademarks of Club Car, Inc.
This manual effective July 28, 2003.

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Summary of Contents for V-GLIDE

Page 1: ...Club Car MANUAL NUMBER 102397604 EDITION CODE 1203A00000 V GLIDE 36 VOLT ELECTRIC VEHICLES 2004 MAINTENANCE SERVICE SUPPLEMENT ...

Page 2: ......

Page 3: ...ises that all repairs and or service be performed by an authorized Club Car distributor dealer representative or by a Club Car factory trained tech nician It is the policy of Club Car Inc to assist its distributors and dealers in continually updating their service knowl edge and facilities so they can provide prompt and efficient service for vehicle owners Regional technical rep resentatives vehic...

Page 4: ...mprove its vehicles and other products These improvements may affect servicing procedures Any modification and or significant change in specifications or proce dures will be forwarded to all Club Car distributors and dealers and will when applicable appear in future editions of this manual Club Car Inc reserves the right to change specifications and designs at any time without notice and without t...

Page 5: ...cuit 11 1 Power Circuit 11 2 Charge Circuit 11 2 Wiring Diagram 11 4 Troubleshooting Guide 11 5 Test Procedures 11 7 Index of Test Procedures 11 7 SECTION 12 ELECTRICAL COMPONENTS Key Switch 12 1 Forward Reverse Anti Arcing Limit Switch 12 3 Accelerator Pedal Limit Switch 12 3 Reverse Buzzer 12 4 Solenoid 12 5 Resistors 12 6 Wiper Switch 12 8 Forward Reverse Switch 12 14 Charger Receptacle 12 15 R...

Page 6: ... 9 Battery Charger Test 13 9 On Charge Voltage Test 13 9 Hydrometer Test 13 9 Discharge Test 13 11 Battery Troubleshooting Examples 13 13 Battery Storage 13 14 Charging a Battery Pack that has Low Voltage 13 14 SECTION 14 BATTERY CHARGER Refer to the appropriate battery charger maintenance and service manual SECTION 15 MOTOR General Information 15 1 External Motor Testing 15 1 Motor 15 3 Motor Com...

Page 7: ... and Assembly 16a 7 Transaxle Disassembly and Inspection 16a 7 Transaxle Assembly 16a 9 Transaxle Installation 16a 10 SECTION 16B TRANSAXLE TYPE K Transaxle Identification 16b 1 Lubrication 16b 1 Axle Bearing and Shaft 16b 1 Axle Shaft 16b 1 Axle Bearing 16b 4 Transaxle 16b 5 Transaxle Removal 16b 5 Transaxle Disassembly Inspection and Assembly 16b 8 Transaxle Disassembly and Inspection 16b 8 Tran...

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Page 9: ... in this manual as well as those on the vehicle and battery charger Only trained technicians should repair or service the vehicle or battery charger Anyone doing even simple repairs or service should have knowledge and experience in electrical and mechanical repair Prior to servicing the vehicle or leaving the vehicle unattended turn the key switch OFF remove the key and place the Forward Reverse ...

Page 10: ...iring could result in vehicle malfunction property damage personal injury or death Improper use of the vehicle or failure to properly maintain it could result in decreased vehicle performance severe personal injury or death Do not leave children unattended on vehicle GENERAL INFORMATION See General Warning on page 10 1 To ensure trouble free vehicle performance it is very important to follow an es...

Page 11: ...king soda water solution Tires Check air pressure and adjust if necessary See Section 2 Specifications in the DS Maintenance and Service Manual Wiper switch Check for cracks or other damage make sure switch is securely fastened to frame Check movable contact for correct operation General vehicle Wash battery compartment and underside of vehicle Semiannual service by trained technician only every 5...

Page 12: ...ings Dry Moly Lube CCI P N 1012151 Brake linkage and pivots Dry Moly Lube CCI P N 1012151 Accelerator push rod pivots and mounts Dry Moly Lube CCI P N 1012151 Forward Reverse switch contacts and charger receptacle WD 40 Brake slides Dry Moly Lube CCI P N 1012151 Front suspension 5 fittings Chassis Lube EP NLGI Grade 2 Annually by trained technician only every 100 hours of operation or 200 rounds o...

Page 13: ...included on every vehicle CONTROL CIRCUIT The control circuit consists of the following Key switch Forward Reverse anti arcing limit switch Accelerator pedal limit switch Solenoid Connecting wires The key switch has two positions ON and OFF and is used to disable open the control circuit when the vehi cle is not in use With the key in the OFF position the vehicle will not operate The Forward Rever...

Page 14: ...g V Glide wiper switch contacts Resistors Forward Reverse switch Solenoid power contacts Motor Batteries All connecting wires The motor and batteries are discussed in separate sections in this manual See Section 15 Motor See also Section 13 Batteries When the control circuit is closed the vehicle will start in first speed As the accelerator pedal is pressed the brush on the wiper switch arm moves ...

Page 15: ...ptacle is damaged or feels hot when charging one or both must be replaced See Charger Receptacle Inspection Section 12 Page 12 16 The onboard receptacle fuse link provides additional protection for the vehicle charging circuit The fuse is rated for use with a Club Car Accu Power Charger only If it is blown the cause should be determined before the fuse is replaced Batteries in a vehicle with a blo...

Page 16: ...ACK BLACK WHITE SPEED SWITCH WHITE FORWARD REVERSE SWITCH REVERSE BUZZER FUSE AND RECEPTACLE ORANGE BLUE RED WHITE WHITE SOLENOID GREEN GREEN BLUE BLACK WHITE RED GREEN WHITE ORANGE YELLOW GREEN BLUE BLACK BROWN PURPLE GREEN RED LIMIT SWITCH YELLOW KEY SWITCH ORANGE RED WHITE BLUE BATTERY BANK BLACK G REEN W H I T E G R A Y B L A C K RESISTOR BOARD MOTOR BROW N PURPLE GRAY RED SOLENOID SNUBBER WHI...

Page 17: ...ed or improperly connected wires at accelerator pedal limit switch Test Procedure 4 Accelerator Pedal Limit Switch on page 11 9 Failed accelerator pedal limit switch Test Procedure 4 Accelerator Pedal Limit Switch on page 11 9 Loose solenoid switch Test Procedure 10 Solenoid Contacts Power Off on page 11 15 and Test Procedure 11 Solenoid Contacts Power On on page 11 15 Failed solenoid coil Test Pr...

Page 18: ...vice Manual Loose wiring at motor Test Procedure 9 Motor on page 11 14 Worn or misaligned motor brushes Section 15 Motor Dirty or rough motor commutator Section 15 Motor Dragging brakes See Section 5 Accelerator and Brake Pedal Group in the DS Golf Car Maintenance and Service Manual Under inflated or flat tires See Section 8 Wheels and Tires in the DS Golf Car Maintenance and Service Manual Vehicl...

Page 19: ...perate in Reverse but not in Forward Improper actuation or faulty Forward Reverse anti arcing limit switch Test Procedure 3 Forward Reverse Anti Arcing Limit Switch on page 11 9 Dirty or corroded Forward Reverse switch contacts See Section 12 Electrical Components Incorrect wiring at batteries See Wiring Diagram on page 11 4 Vehicle not being fully charged Loose wires at charger receptacle batteri...

Page 20: ...he red probe of a multimeter set at Ω on the forward terminal of the Forward Reverse switch and place the black probe on the upper COM terminal of the Forward Reverse anti arcing limit switch Figure 11 4 Page 11 8 With the key in the OFF position the reading should be no continuity 3 Insert the key and turn the key switch to the ON position The reading should be continuity 4 If the reading is inco...

Page 21: ... avoid unintentionally starting in General Warning Section 10 Page 10 1 2 Place the red probe of the multimeter set to 200 Ω on the terminal of the green wire at its connection on the activating coil post of the solenoid and place the black probe on the negative post of battery no 6 Figure 11 6 Page 11 9 With the accelerator pedal fully up not pressed the reading should be no continuity 3 Press th...

Page 22: ...o avoid unintentionally starting in General Warning Section 10 Page 10 1 2 Remove the center dash panel See step 2 of Key Switch Removal Section 12 Page 12 1 3 Disconnect the 18 gauge white wire at the reverse buzzer Place the red probe of a multimeter set to 200 Ω on the large post of the solenoid with the 6 gauge and the 18 gauge white wires attached and place the black probe on the terminal end...

Page 23: ...ot resistors can cause severe burns Figure 11 8 Reverse Buzzer Test White Wire Figure 11 9 Reverse Buzzer Test Orange Wire Figure 11 10 Resistor Test 2m 20 m 200 m 2k 200 200 200 200 20 2 200 m 500 20k 200k 2000 k Ω Ω 1000 OFF WAVETEK 5XL V V V A COM 200nA MAX 1000 750V FUSED SOLENOID REVERSE BUZZER 18 GAUGE WHITE WIRE 18 GAUGE ORANGE WIRE 2m 20 m 200 m 2k 200 200 200 200 20 2 200 m 500 20k 200k 2...

Page 24: ... lug of the switch with brown wire attached and place the black probe on the mov able contact with the purple wire attached on the forward and reverse rotor Figure 11 11 Page 11 12 The reading should be continuity 2 2 With the Forward Reverse switch in the FORWARD position place the red probe on the forward terminal lug with the 6 gauge red wire attached of the Forward Reverse switch and place the...

Page 25: ...s positive cable first and tighten to 110 in lb 12 4 N m Coat with Battery Terminal Protector Spray CCI P N 1014305 to minimize corrosion Figure 11 13 Forward Reverse Switch Test Step 2 3 Figure 11 14 Forward Reverse Switch Test Step 2 4 Figure 11 15 Forward Reverse Switch 2m 20 m 200 m 2k 200 200 200 200 20 2 200 m 500 20k 200k 2000 k Ω Ω 1000 OFF WAVETEK 5XL V V V A COM 200nA MAX 1000 750V FUSED...

Page 26: ...orward Reverse handle in the NEUTRAL position place the red probe on the common terminal lug of the Forward Reverse switch brown wire and place the black probe on the negative post of battery no 6 The reading should be continuity Figure 11 17 Page 11 14 3 If either reading in step 2 is incorrect check for loose wires or terminals Refer to Section 15 Motor for further testing and repair procedures ...

Page 27: ... snubber See Section 12 Electrical Components TEST PROCEDURE 11 SOLENOID CONTACTS POWER ON See General Warning Section 10 Page 10 1 DANGER Before connecting the batteries disconnect the gray wire from the resistor board to the A2 motor terminal and remove the wire from the vehicle Then raise the rear end of the vehicle until the rear wheels are off the floor See WARNING Lift only one end of the ve...

Page 28: ...handle in the NEUTRAL position and disconnect batteries negative cable first as shown in Section 10 Figure 10 1 Page 10 2 before replacing solenoid or installing gray wire from resistor board to A2 motor terminal TEST PROCEDURE 12 V GLIDE WIPER SWITCH See General Warning Section 10 Page 10 1 1 Remove the V Glide wiper switch cover and observe the wiper arm brush as it moves across the fixed contac...

Page 29: ...g or fixed contacts are damaged the entire wiper switch housing with contacts must be replaced 4 Make sure nuts attaching wires to the backs of the fixed contacts are tightened to 40 in lb 4 5 N m Figure 11 21 Wiper Arm Brush and Fixed Contacts Figure 11 22 Wiper Arm Brush Wear Limit Line RIGHT WRONG WRONG Wiper arm brush and fixed contacts should seat firmly against each other WIPER ARM BRUSH FIX...

Page 30: ...11 ...

Page 31: ...moval 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning Section 10 Page 10 1 2 Remove the center dash panel 2 1 Remove the plastic cap 1 covering the mounting screw 2 on each side of the center dash panel 3 Figure 12 1 Page 12 1 2 2 Loosen but do not remove the screw 2 on each side of the center dash panel 3 2 3 Insert screwdriver at the...

Page 32: ...e the key switch cap 8 Hold the key switch and remove the switch retaining nut 6 from the out side of the dash panel Figure 12 2 Page 12 2 Key Switch Installation 1 Position the key switch and flat washer 9 in the center dash then install and tighten the switch retaining nut 6 to 40 in lb 4 5 m Install key switch cap 8 in the center dash Figure 12 2 Page 12 2 2 Refer to the wiring diagram to conne...

Page 33: ...mit Switch Installation 1 Position the anti arcing limit switch 2 on the Forward Reverse switch housing and install the screws lock washers and nuts Tighten the screws to 5 in lb 0 6 N m Figure 12 3 Page 12 3 2 Connect the blue wire 9 to the common COM terminal 6 and the yellow wire 8 to the normally open NO terminal 7 Figure 12 3 Page 12 3 3 After installation make sure the switch makes an audibl...

Page 34: ... wire 35 to the normally closed NC terminal and the black wire 36 to the common COM terminal of the limit switch The normally open NO terminal should have no wire attached to it 4 Install cover 10 on V Glide wiper switch make sure all three tabs snap into place 5 Install the no 5 and no 6 batteries and connect battery cables positive cable first Tighten terminal hard ware to 110 in lb 12 4 N m See...

Page 35: ...mbly onto small solenoid posts Make sure the direction of the diode is correct The red insulated terminal of the diode assembly should be installed on the same post that the 18 gauge yellow wire is attached and the clear insulated terminal of the diode assembly should be installed on the same post that the 18 gauge green wire is attached Figure 12 5 Page 12 6 See following WARNING WARNING Do not d...

Page 36: ...General Warning Section 10 Page 10 1 The resistors are attached to the resistor mounting board which is located behind the batteries Testing the Resistors See Test Procedure 7 Section 11 Page 11 11 Resistor Removal 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning Section 10 Page 10 1 2 Loosen but do not remove the nuts 1 that secure the...

Page 37: ...nd NOTE CAUTION Be sure the motor wires are secured in wire ties so they cannot come into contact with the resistors Be sure resistors are no closer than one inch to resistor shield If resistors are closer than one inch to resistor shield adjust the resistors If a 3 1 2 horsepower motor is being used in conjunction with a V Glide wiper switch the fourth and fifth speed resistor coils must be repla...

Page 38: ...mbly is securely fastened to the frame after installation The V Glide wiper switch assembly should be inspected on a monthly basis for cracks or damage and to verify it is securely attached to the vehicle frame See following CAUTION CAUTION Inspect the V Glide wiper switch housing for cracks or damage before installation If the housing is cracked or damaged the entire housing with fixed contacts m...

Page 39: ...tch adjustment To ensure proper vehicle operation if any one item requires adjustment all must be checked and adjusted if necessary in the order listed WARNING To properly adjust wiper switch check and adjust if necessary the following items in the order listed Brake pedal and cable adjustment See Section 5 in the DS Golf Car Maintenance and Service Manual Accelerator rod adjustment See Section 5 ...

Page 40: ...and place the wiper switch arm on the topmost fixed contact Figure 12 9 Page 12 10 3 Remove the cap protector 25 nut 30 and lock washer 31 from the bolt 9 and remove the two 6 gauge white wires 32 and 33 4 Remove the second nut 3 from the bolt 9 and then remove the bolt from the V Glide wiper switch hous ing 1 Figure 12 9 V Glide Wiper Switch 31 30 TYPICAL 8 PLACES TYPICAL 5 PLACES Club Car 37 13 ...

Page 41: ...er switch cover 10 13 Install the no 5 and no 6 batteries 14 Connect the battery cables positive cable first and tighten to 110 in lb 12 4 N m Coat with Battery Terminal Protector Spray CCI P N 1014305 to minimize corrosion Wiper Switch Removal 1 Remove battery nos 5 and 6 from the vehicle See Figure 10 1 Section 10 Page 10 2 2 Remove nuts 30 and lock washers 31 then remove resistor wires from wip...

Page 42: ...erminal lock washer and nut through switch housing 8 Install the nut 3 onto the bolt and tighten to 40 in lb 4 5 N m See following WARNING WARNING Make sure the wiper switch arm rotates freely in the housing If the arm binds or sticks it must be replaced 9 Adjust the wiper switch See Wiper Switch Adjustment on page 12 9 Wiper Switch Installation CAUTION Before installing the wiper switch inspect t...

Page 43: ...o the sixth contact from the bottom and tighten the nut to 40 in lb 4 5 N m 9 Connect the 6 gauge blue wire to the seventh contact from the bottom and tighten nut to 40 in lb 4 5 N m 10 Connect the 6 gauge black wire to the eighth contact from the bottom and tighten the nut to 40 in lb 4 5 N m See following WARNING and CAUTION WARNING Make sure wires are connected to V Glide wiper switch contacts ...

Page 44: ...and reverse movable contact and stationary contacts Make sure the stationary contacts are in good condition If they are not replace the entire forward and reverse assembly If severe arc ing has occurred check the forward and reverse anti arcing limit switch for proper operation Keep the For ward Reverse switch clean If the Forward Reverse switch is stiff or binds in operation lubricate the contact...

Page 45: ...act from turning 4 Reconnect the 18 gauge wires to the limit switch See following WARNING WARNING Make sure wires are properly connected to Forward Reverse switch If wires are not properly connected the vehicle may operate in an unexpected manner resulting in property damage severe personal injury or death 5 Place handle 2 on Forward Reverse switch Tighten screw 3 to 14 in lb 1 6 N m Figure 12 11 ...

Page 46: ...elt the receptacle must be replaced Charger Receptacle Removal 1 Remove key and place Forward Reverse handle in the NEUTRAL position Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning Section 10 Page 10 1 2 Disconnect the small black wire 15 and the white wire 14 to the negative battery post from the neg ative terminal of the receptacle Fig...

Page 47: ... rear portion of the charger recepta cle Figure 12 12 Page 12 16 Refer to the appropriate battery charger maintenance and service manual See following WARNING WARNING Under normal operating conditions the receptacle fuse link should never fail unless there is an electrical problem If the fuse blows determine the cause of the problem and correct it before replacing the fuse Receptacle Fuse Link Rem...

Page 48: ...12 ...

Page 49: ... The average amperage draw is considered to be 75 amps on a 36 volt vehicle although it varies greatly depending on the vehicle and how it is operated Deep cycle vehicle batteries are specifically designed to handle this type of service The rechargeable lead acid battery turns chemical energy into electrical energy and vice versa The main active elements within a battery are the positive plates th...

Page 50: ...cted to a charger the process is reversed The sulfate SO4 is forced from the plates back into the electrolyte to make sulfuric acid H2SO4 The oxygen returns to the positive plate to make lead dioxide PbO2 Figure 13 4 Page 13 2 The result is a charged battery that is again capable of generating electricity Figure 13 1 Page 13 2 Figure 13 1 Charged Battery Figure 13 2 Discharging Battery Figure 13 3...

Page 51: ...ITY Deep discharge This vehicle is running slowly but we can run it until it stops Avoid deep discharge of batteries whenever possible See Deep Discharge on page 13 7 Early excessive discharging These are new batteries They can run all day New batteries do not reach their full capacity until they have been used and recharged 20 to 50 times See Early Excessive Discharging on page 13 7 Mineral conte...

Page 52: ...buckle battery case Tighten to 40 in lb 4 5 N m alternating between hold down bolts 6 Install wires in proper sequence Figure 13 5 Page 13 4 Install black wire to negative post of bat tery no 6 last Make sure all connections are tight Tighten to 110 in lb 12 4 N m Coat all terminals with Battery Terminal Protector Spray CCI P N 1014305 to minimize future corrosion 7 Give the batteries a full charg...

Page 53: ...discharge batteries should always be kept clean Hot weather also has an effect on a battery s self discharge rate The higher the temperature the quicker a set of batteries will discharge In hotter climates batteries should be checked more often When storing batteries keep in a cool place See Battery Storage on page 13 14 ELECTROLYTE LEVEL CAUTION Do not allow battery acid from battery caps or hydr...

Page 54: ... of the battery It may also cause acid to leak out of the vent caps and corrosion to build up on surrounding metal parts The acid which is lost reduces the capacity of the battery and cannot be replaced Battery hold downs should NOT be so tight as to crack or buckle the battery case This may cause leaks which would dry out a cell or cause internal short circuits See Battery Replacement on page 13 ...

Page 55: ...20 to 50 times If they are excessively discharged early in their life their effective service life will be shortened It is advisable to limit the use of any vehicle with new batteries for at least the first four weeks and then grad ually increase their range INCOMING AC SERVICE Make sure the incoming AC line service is sufficient If circuit breakers are tripping fuses blow during the night or the ...

Page 56: ...ve 7 0V and within 0 5V All readings below 7 0V but within 0 5V Check electrical system and charger for problems SeeTroubleshooting Guide If problem is not found go to on charge voltage test Any reading below 7 0 volts and not within 0 5 volts of those batteries above 7 0 volts replace battery Replace any battery with a variation of more than 50 points of specific gravity between cells or has a ce...

Page 57: ...igure 13 5 Page 13 4 Record reading Then set multimeter to 20 volts DC and place the red probe on the positive post and the black probe on the negative post of each battery Record the readings The on charge voltage for the set should be between 42 0 volts and 47 4 volts depending on the age and state of charge of the batteries being tested If individual batteries read above 7 0 volts and are withi...

Page 58: ...C The readings obtained as described above must be corrected for temperature For each 10 F 5 6 C above 80 F 26 7 C add 0 004 to the reading For each 10 F 5 6 C below 80 F 26 7 C subtract 0 004 from the reading Interpreting the Results of the Hydrometer Test The approximate state of charge can be determined from the following table If the difference between the cells is 0 020 or more the low cell s...

Page 59: ...ttery no 1 and negative post of battery no 6 Figure 13 9 Page 13 11 VEHICLE NO BATTERY NO ELECTROLYTE TEMPERATURE CORRECTION FACTOR CORRECTED SPECIFIC GRAVITY REQUIRED ACTION POSITIVE CELL CENTER CELL NEGATIVE CELL 12 1 20 F 6 6 C 0 024 1 275 0 024 1 251 1 280 0 024 1 256 1 280 0 024 1 256 Sound battery fully charged 35 6 90 F 32 2 C 0 004 1 155 0 004 1 159 1 165 0 004 1 169 1 160 0 004 1 164 Disc...

Page 60: ... with the batteries 2 If discharge times are low less than 60 minutes replace batteries below 5 0 volts 3 In general battery sets that discharge in less than 60 minutes at 78 F 25 6 C on the discharge test will typically not hold a charge for an entire work shift However discharge time is dependent on the elec trolyte temperature The table shown gives the discharge times at various temperatures of...

Page 61: ... closely but appears to be okay Battery no 1 should be replaced with a bat tery that has about the same age and usage as the other batteries in the set Example 2 Vehicle no 70 was also suspected of having a bad battery due to its performance The battery charger test showed 7 0 amps after a full charge After confirming there were no problems with the electrical system charger or brakes the on charg...

Page 62: ...ate of charge periodically Batteries that are discharged and left in a cold environment can freeze and crack If the specific gravity drops below 1 220 the batteries should be recharged See the following chart 5 The frequency of recharging required will depend on the temperature of the storage area but it is rec ommended the batteries be monitored for state of charge every month Also if the storage...

Page 63: ...2004 V Glide 36 Volt Electric Vehicle Maintenance and Service Supplement Page 14 1 14 SECTION 14 BATTERY CHARGER Refer to the appropriate battery charger maintenance and service manual ...

Page 64: ...14 ...

Page 65: ...Warning Section 10 Page 10 1 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning Section 10 Page 10 1 2 Disconnect wires from terminals on motor using two wrenches to prevent the post from turning 3 Set a multimeter to 200 Ω ohms and place the black probe on the motor housing Scratch through the paint to ensure a good connection Place the ...

Page 66: ...indings may be the cause The motor will need to be removed from the vehicle and repaired by a qualified technician See Motor Removal on page 15 3 TEST PROCEDURE 3 FIELD CIRCUIT OPEN See General Warning Section 10 Page 10 1 1 Disconnect the battery cables as instructed See WARNING To avoid unintentionally starting in General Warning Section 10 Page 10 1 2 Disconnect the wires from the motor S1 and ...

Page 67: ...the vehicle to let the jack stands support the vehicle Figure 15 3 Page 15 3 See following WARNING WARNING Lift only one end of the vehicle at a time Use a suitable lifting device chain hoist or hydraulic floor jack with 1000 lb 454 kg minimum lifting capacity Do not use lifting device to hold vehicle in raised position Use approved jack stands of proper weight capacity to support the vehicle and ...

Page 68: ...the motor end shield and stator shell then place the motor in a vice with wooden blocks as shown Figure 15 5 Page 15 5 2 Remove the four bolts 8 securing the end shield 10 to the stator shell 2 3 Remove the two screws 9 attaching the end shield to the bearing retainer 4 Slide the armature 17 out of the opposite end of the stator shell 2 5 Remove the two screws 11 attaching the brush rigging 12 to ...

Page 69: ...emble the motor and carefully inspect the armature for the following characteristics Burned charred or cracked insulation Improperly cured varnish Thrown solder Flared armature windings Damaged armature core laminations Worn burned or glazed commutators Dirty or oily commutators Raised commutator bars Worn armature bearing or shaft Figure 15 5 Motor Disassembly Figure 15 6 Brush Spring Removal S 1...

Page 70: ...OTE Oil on the commutator may indicate a faulty transaxle input shaft oil seal Armature Ground Test CAUTION Do not submerge the armature in solvent NOTE Before testing the armature wipe it clean with a clean cloth Remove any carbon dust and metal particles from between the commutator bars 1 With a multimeter set to 200 Ω ohms place one probe on the commutator and the other on the armature core The...

Page 71: ...move and replace brushes one at a time This method ensures the terminals and brushes will be properly positioned in the rigging Refer to Motor Assembly for brush installation See Motor Assembly on page 15 10 When replacing brushes replace all four brushes Never replace only two Install the brushes in the same rigging 180 apart from each other BEARING INSPECTION 1 Using a clean cloth wipe the carbo...

Page 72: ...ge 15 8 2004 V Glide 36 Volt Electric Vehicle Maintenance and Service Supplement 15 Figure 15 10 Motor 30 24 25 1 2 3 4 6 8 16 15 7 14 13 12 9 17 TYPICAL 4 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES 11 10 5 27 28 22 23 TYPICAL 3 PLACES S 1 A 1 S 2 A 2 ...

Page 73: ...ARING INSTALLATION 1 Press a new bearing 15 onto the armature Figure 15 10 Page 15 8 Use an arbor press that exerts pressure on the inner race only See following NOTE NOTE Make sure the bearing retainer 16 is positioned on the armature shaft before the bearing is pressed onto the armature Figure 15 10 Page 15 8 An arbor with an outside diameter of less than 5 8 inch 16 mm should be used to press t...

Page 74: ...e threaded holes in the mounting bracket Figure 15 12 Page 15 11 Tighten the screws to 20 in lb 2 2 N m 2 2 One at a time push brush spring extensions back from brushes and slide the brushes back until they are completely retracted into their mounting slots Then position the brush springs against the sides of the brushes so that spring pressure will hold them in the retracted position Figure 15 6 ...

Page 75: ...while starting the first mounting screw Figure 15 13 Page 15 11 3 2 Align the match marks on the end shield and the stator shell then install the four screws 8 Figure 15 10 Page 15 8 Tighten the screws to 90 in lb 10 N m 4 Make sure the armature turns freely If it does not turn freely disassemble the motor to find the problem Make sure the bearing is properly seated in the end shield when assembli...

Page 76: ...sure these areas are completely clean of grease as shown Figure 15 16 Page 15 13 3 Install the molded bumper 3 1 With the flat side toward the bottom of the coupling install the molded bumper 30 into the motor coupling Figure 15 10 Page 15 8 See following NOTE NOTE The motor coupling and the new molded bumper must be new and free of grease and debris 3 2 Ensure that the installed bumper is seated ...

Page 77: ...d to the proper tightness may result in motor noise during operation 4 4 Tighten the bolt 24 inserted through the tab to 155 in lb 17 5 N m Figure 15 18 Page 15 13 4 5 Tighten the center bolt 2 to 65 in lb 7 3 N m Figure 15 19 Page 15 13 4 6 Tighten the right bolt 3 to 65 in lb 7 3 N m 4 7 Tighten the left bolt 4 to 65 in lb 7 3 N m 4 8 Install the motor wires making sure they are connected to the...

Page 78: ... cup washer 8 Install the wheels and finger tighten the lug nuts 9 Lift vehicle and remove jack stands Lower vehicle to the floor and tighten lug nuts using a crisscross pat tern to 55 ft lb 74 6 N m 10 Connect the battery cables positive cable first and tighten to 110 in lb 12 4 N m Coat with Battery Terminal Protector Spray CCI P N 1014305 to minimize corrosion 11 Inspect the vehicle for proper ...

Page 79: ... Warning Section 10 Page 10 1 There are two plugs located on the lower half of the transaxle housing The upper plug 21 as viewed when the vehicle is on a level surface is used as a lubricant level indicator Figure 16a 5 Page 16a 3 When the vehicle is parked on a level surface the lubricant level should be even with the bottom of the hole The lower plug 22 is for draining the lubricant When drainin...

Page 80: ... the inside surfaces of the tube when removing the oil seal and adapter ring A damaged tube might have to be replaced NOTE Do not discard the adapter ring If the adapter ring is lost or damaged the axle tube will have to be replaced 5 2 Use a press to separate the axle oil seal 15 from the adapter ring 39 Figure 16a 3 Page 16a 2 Retain the adapter ring and discard the oil seal 6 Inspect the axle s...

Page 81: ... V Glide 36 Volt Electric Vehicle Maintenance and Service Supplement Page 16a 3 16A Figure 16a 5 Transaxle Type G 1 3 4 14 15 24 26 34 13 33 36 32 8 9 10 11 12 20 18 19 16 16 16 17 23 21 25 36 22 35 13 27 30 31 29 2 3 8 9 36 15 27 30 28 37 38 5 6 ...

Page 82: ...o the axle tube Be careful not to damage the seal Then advance the shaft through the inner bearing and rotate it to align the shaft splines with the splined bore of the differential side gear 27 Figure 16a 5 Page 16a 3 Con tinue advancing the shaft until the bearing seats against the axle tube shoulder 3 Use a pair of snap ring pliers to install the retaining ring 6 inside axle tube Figure 16a 5 P...

Page 83: ... one lug nut onto a stud on each rear hub This will keep the brake drums on the hubs 4 Remove the bow tie pins 1 brake cable clevis pins 2 and cable retaining E clips 3 Disconnect the brake cables 4 Figure 16a 7 Page 16a 5 5 Disconnect the shock absorbers from their lower mounts Figure 16a 8 Page 16a 5 6 Disconnect the four motor wires Use two wrenches to prevent the post from turning 7 With a flo...

Page 84: ... from the transaxle until the motor spline becomes disengaged from the input shaft then lift motor out See preceding CAUTION 11 If a floor jack was used pull floor jack from beneath the transaxle and allow the springs to rest on the floor 12 Remove the U bolts attaching the transaxle to the leaf springs Figure 16a 10 Page 16a 6 13 Carefully lift each end of the transaxle off its positioning pin on...

Page 85: ...mating seal surfaces use caution when separating halves 4 Remove input pinion gear 17 by pulling gear out while rocking intermediate gear assembly 19 Lift intermediate gear assembly and differential gear case unit out simultaneously Figure 16a 5 Page 16a 3 See following CAUTION CAUTION Do not damage gears Use extreme care when handling them 5 Use a bearing puller or arbor press to remove bearings ...

Page 86: ...34 from between the ring gear and differential case for reassembly 8 3 Separate the differential gear case housing If necessary reinstall two of the hex bolts removed previously in step 8 1 into the differential gear unit and while holding the unit slightly above the work area lightly tap the bolt heads Figure 16a 14 Page 16a 8 Remove the two bolts 8 4 Remove the differential pin 31 by pushing pin...

Page 87: ...ing an arbor press Figure 16a 5 Page 16a 3 2 Assemble the differential gear case 2 1 Install the pin 31 Figure 16a 5 Page 16a 3 Apply a small amount of oil to all thrust plates and to both ends of the pin 2 2 Install four hex bolts 33 and output gear 32 Tighten bolts to 51 ft lb 69 N m 3 Press a new bearing 18 onto the intermediate gear assembly Figure 16a 5 Page 16a 3 4 Press new bearing 16 onto ...

Page 88: ...ifferential side gear Push the shaft in until the bearing seats against the shoulder in the axle tube 12 Install the retaining ring 6 in the axle tube See following WARNING WARNING Be sure the retaining ring is properly seated in its groove If the ring is not properly installed the axle assembly will separate from the transaxle and damage the axle assembly and other components Loss of vehicle cont...

Page 89: ... See following NOTE NOTE If the motor wires were not tagged when disconnected refer to the wiring diagram for proper con nection See Wiring Diagram Section 11 Page 11 4 7 Insert bolts through the spring shackles and bushings in the leaf spring eyes Secure bolts with lock nuts Tighten to 15 ft lb 20 3 N m 8 Connect the brake cables 9 Install the shock absorbers Tighten shock absorber retaining nuts...

Page 90: ...16A ...

Page 91: ...rning Section 10 Page 10 1 There are two plugs located on the lower half of the transaxle housing The upper plug 25 as viewed when the vehicle is on a level surface is used as a lubricant level indicator Figure 16b 4 Page 16b 3 When the vehicle is parked on a level surface the lubricant level should be even with the bottom of the hole The lower plug 44 is for draining the lubricant When draining t...

Page 92: ... 16 inch 40 cm rolling wedge bar Figure 16b 2 Page 16b 2 to remove oil seal Insert the wedge bar underneath the seal lip and pry out oil seal 17 Figure 16b 3 Page 16b 2 See following CAU TION CAUTION Do not scar or damage the inside surfaces of the tube when removing the oil seal A damaged tube might have to be replaced 6 Inspect the axle shaft assembly to be sure the bearing and collar have not s...

Page 93: ...lt Electric Vehicle Maintenance and Service Supplement Page 16b 3 16B Figure 16b 4 Transaxle Type K 37 31 30 29 28 27 41 26 6 5 17 4 7 2 3 20 21 23 18 18 4 16 7 17 5 6 25 22 38 14 44 39 8 9 32 36 34 35 34 33 14 37 40 1 3 8 9 12 11 10 42 43 13 24 18 19 7 4 6 5 ...

Page 94: ...e removed Axle Bearing Installation 1 If removed place retaining ring 6 on axle shaft 1 or 2 Figure 16b 4 Page 16b 3 The retaining ring will be loose on the axle shaft until it is installed into the axle tube 2 Apply two drops of Loctite 271 to the inside of the collar See following CAUTION CAUTION Apply Loctite 271 to inside of collar only not to the shaft so the Loctite will be pushed away from ...

Page 95: ...d end of the axle shaft and from the oil seal area prior to installing the axle shaft 3 Clean the shaft splines and then insert the shaft splined end first through the seal and into the axle tube Be careful not to damage the seal Then advance the shaft through the inner bearing and rotate it to align the shaft splines with the splined bore of the differential side gear 37 Figure 16b 4 Page 16b 3 C...

Page 96: ...hub This will keep the brake drums on the hubs 4 Remove the bow tie pins 1 brake cable clevis pins 2 and cable retaining E clips 3 Disconnect the brake cables 4 Figure 16b 8 Page 16b 6 5 Disconnect the shock absorbers from their lower mounts Figure 16b 9 Page 16b 6 6 Disconnect the four motor wires Use two wrenches to prevent the post from turning 7 With a floor jack supporting the transaxle remov...

Page 97: ...saxle until the motor spline becomes disengaged from the input shaft then lift motor out See preceding CAUTION 11 If a floor jack was used pull floor jack from beneath the transaxle and allow the springs to rest on the floor 12 Remove the U bolts attaching the transaxle to the leaf springs Figure 16b 11 Page 16b 7 13 Carefully lift each end of the transaxle off its positioning pin on the leaf spri...

Page 98: ...3 Pull the halves of the housing 11 and 24 apart If necessary tap lightly on the spline of the input pinion 19 See following CAUTION CAUTION To prevent damage to the housing mating seal surfaces use caution when separating halves 4 Remove input pinion gear 19 by pulling gear out while rocking intermediate gear assembly 23 Lift intermediate gear assembly and differential gear case unit out simultan...

Page 99: ...to the ring gear 30 Figure 16b 4 Page 16b 3 See also Figure 16b 16 Page 16b 9 9 2 Remove eight hex bolts 28 that secure the ring gear to the differential case Figure 16b 4 Page 16b 3 9 3 Remove the ring gear Retain dowel pin 41 from between the ring gear and differential case for reassembly 9 4 Separate the differential gear case housing If necessary reinstall two of the hex bolts removed previous...

Page 100: ...ge Any worn or damaged parts should be replaced See following NOTE NOTE Damaged or worn gears should be replaced as sets TRANSAXLE ASSEMBLY CAUTION Do not press against the bearing outer race Gasket 13 faces of the housing must be clean and smooth Use only a new gasket that is not torn or damaged The gasket must lie flat against the housing faces Figure 16b 4 Page 16b 3 The housing and all parts m...

Page 101: ...all left half of transaxle housing 8 1 Place a 1 8 inch 3 mm bead of Three Bond liquid gasket on mating surface of housing 8 2 Install left half of transaxle housing 24 Figure 16b 4 Page 16b 3 8 3 Install the ten bolts 26 and tighten to 69 in lb 7 8 N m 8 4 If the axle tube 16 and 40 was removed install the shims 39 if the shims were removed and Three Bond liquid gasket Install the axle tube with ...

Page 102: ...ed the transaxle may need new shims To determine whether new shims are necessary the transaxle must be completely assembled except for the short axle tube 16 and both axle shafts 1 and 2 Figure 16b 4 Page 16b 3 1 Stand the transaxle on end on the axle tube 2 Using a depth gauge measure the distance from the gasket seal surface of the axle tube to the outer race of the bearing 14 on the differentia...

Page 103: ...ngs into the rear spring shackles If using a floor jack raise the differential while guiding the leaf springs into the rear spring shackles Then raise the jack stands to support the transaxle 6 Connect the four motor wires Tighten the retaining nuts to 65 in lb 7 3 N m Use two wrenches to pre vent the posts from turning See following NOTE NOTE If the motor wires were not tagged when disconnected r...

Page 104: ...16B ...

Page 105: ...t 11 2 numbering vehicles and chargers 13 7 testing 13 9 on charge voltage test 13 9 troubleshooting automatic shut off malfunction 13 7 bearing axle see transaxle type g axle bearing see transaxle type k axle bearing bearing motor see motor brush wiper switch see wiper switch C charger receptacle fuse link 12 17 installation 12 17 removal 12 17 inspection 12 16 installation 12 17 removal 12 16 te...

Page 106: ...sistor installation 12 7 removal 12 6 testing 11 11 reverse buzzer installation 12 4 removal 12 4 testing 11 10 S service schedule see periodic service schedule see also periodic lubrication schedule snubber solenoid see solenoid snubber solenoid 12 5 installation 12 5 removal 12 5 testing 11 10 11 15 solenoid snubber 12 6 T test procedures 1 batteries voltage check 11 8 2 key switch 11 8 3 forwar...

Page 107: ... identification 16b 1 inspection 16b 8 installation 16b 13 lubrication 16b 1 oil seal installation 16b 5 removal 16b 1 removal 16b 5 shimming 16b 12 troubleshooting batteries troubleshooting examples 13 13 troubleshooting guide 11 5 W water level see batteries electrolyte level wiper switch 12 8 adjustment 12 9 arm adjustment 12 8 assembly 12 11 brush replacement 12 10 disassembly 12 11 installati...

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Page 109: ...2004 V Glide 36 Volt Electric Vehicle Maintenance and Service Supplement ...

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Page 112: ...Golf Cars and Utility Vehicles Club Car Inc P O Box 204658 Augusta GA 30917 4658 ...

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