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Club Car V-GLIDE Maintenance Service Supplement

36-volt electric vehicles
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2004
MAINTENANCE
SERVICE
SUPPLEMENT
V-GLIDE 36-VOLT
ELECTRIC VEHICLES
MANUAL NUMBER 102397604
EDITION CODE 1203A00000

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Summary of Contents for Club Car V-GLIDE

  • Page 1 2004 MAINTENANCE SERVICE SUPPLEMENT V-GLIDE 36-VOLT ELECTRIC VEHICLES MANUAL NUMBER 102397604 EDITION CODE 1203A00000...
  • Page 3 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.
  • Page 4 NOTE: This manual represents the most current information at the time of publication. Club Car, Inc. is continually working to further improve its vehicles and other products. These improvements may affect servicing procedures.

  • Page 5: Table Of Contents

    Forward/Reverse Switch ........................12-14 Charger Receptacle .......................... 12-15 Receptacle Fuse Link ........................12-17 SECTION 13 – BATTERIES General Information .......................... 13-1 Common Misconceptions About Batteries ..................13-3 Battery Replacement ........................13-3 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement Page iii...
  • Page 6 Motor Components ........................15-7 Bearing Inspection ........................15-7 Bearing Removal .......................... 15-9 Bearing Installation ........................15-9 Reconditioning the Motor ......................... 15-9 Motor Assembly ..........................15-10 Motor Installation ..........................15-11 Page iv 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement...
  • Page 7 Transaxle Disassembly, Inspection, and Assembly ................16b-8 Transaxle Disassembly and Inspection ..................16b-8 Transaxle Assembly ........................16b-10 Shimming the Transaxle ....................... 16b-12 Transaxle Installation ........................16b-13 SECTION i – INDEX 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement Page v...

  • Page 9: Section 10 - Periodic Maintenance

    • Check the vehicle owner’s manual for proper location of all vehicle safety and operation decals and make sure they are in place and are easy to read. WARNING CONTINUED ON NEXT PAGE... 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement Page 10-1...

  • Page 10: General Information

    Any vehicle not functioning correctly should be removed from use until it is properly repaired. This will prevent further damage to the vehicle and avoid the possibility of injury due to unsafe conditions. Contact your local Club Car distributor/dealer to perform all repairs and semiannual and annual periodic service. FRONT...
  • Page 11 • If any problems are found during scheduled inspection or service, do not operate the vehicle until repairs are made. Failure to make necessary repairs could result in fire, property 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement Page 10-3...

  • Page 12: Periodic Lubrication Schedule

    22 oz. (0.67 liter) SAE 30 WT. API, class Check/fill transaxle to plug level hours of operation or 200 SE, SF, or SG oil (or higher) rounds of golf) FLOORBOARD Figure 10-2 V-Glide 36-Volt Vehicle Lubrication Points Page 10-4 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement...

  • Page 13: Section 11 - Electrical System And Testing

    To properly service and maintain the V-Glide 36-volt vehicle, it is necessary to understand the electrical cir- cuitry and the functions of all the electrical components (Figure 11-2, Page 11-4) . On the V-Glide 36-volt vehi- cle, there are three separate circuits: 1) the control circuit, 2) the power circuit, and 3) the charge circuit. A reverse buzzer is also included on every vehicle.

  • Page 14: Power Circuit

    Control Circuit, Continued: As the accelerator pedal is pressed, the lever of the accelerator pedal limit switch is released by the V-Glide wiper arm, closing that portion of the control circuit. When the accelerator pedal is fully upright, the V-Glide wiper arm presses the accelerator pedal limit switch lever and keeps that portion of the control circuit open.
  • Page 15 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 blown fuse will not accept a charge. See Receptacle Fuse Link, Section 12, Page 12-17.

  • Page 16: Wiring Diagram

    ELECTRICAL SYSTEM AND TESTING Wiring Diagram WIRING DIAGRAM DIODE BULLET CONNECTOR SPEED SWITCH BATTERY BANK RESISTOR BOARD MOTOR Figure 11-2 Wiring Diagram Page 11-4 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement...

  • Page 17: Troubleshooting Guide

    Test Procedure 9 – Motor on page 11-14, Motor circuits open see also Section 15 – Motor Motor brushes worn Test Procedure 9 – Motor on page 11-14 Troubleshooting Guide continued on next page... 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement Page 11-5...
  • Page 18 Pedal Group in the DS Golf Car pedal is stuck Maintenance and Service Manual V-Glide wiper switch is improperly See Wiper Switch, Section 12 – Electrical adjusted Components Troubleshooting Guide continued on next page... Page 11-6 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement...

  • Page 19: Test Procedures

    4. Accelerator Pedal Limit Switch 5. Solenoid Activating Coil 6. Reverse Buzzer 7. Resistors 8. Forward/Reverse Switch 9. Motor 10. Solenoid Contacts (Power Off) 11. Solenoid Contacts (Power On) 12. V-Glide Wiper Switch 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement Page 11-7...
  • Page 20 See Section 12 – Electrical Components. 5. 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. Page 11-8 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement...
  • Page 21 3. Press the accelerator pedal. The reading should be continuity. 4. If either reading is incorrect, remove the V-Glide wiper switch housing cover and check for proper acti- vation of the limit switch by the wiper arm. 5. Also make sure the 18-gauge green wire is connected to the normally closed (NC) terminal of the limit switch, and the 18-gauge black wire is connected to the common (COM) terminal.
  • Page 22 (+) probe on the terminal end of the 18-gauge orange wire at the reverse buzzer. The multimeter should indicate continuity. If not, replace the 18-gauge orange wire (Figure 11-9, Page 11-11). Page 11-10 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement...
  • Page 23 WARNING • Do not touch hot resistors! Hot resistors can cause severe burns. RESISTOR WAVETEK 1000 2000 200k Ω Ω 200nA 1000 --- FUSED 750V Figure 11-10 Resistor Test 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement Page 11-11...
  • Page 24 (with brown wire attached) of the Forward/Reverse switch, and place the black (–) probe on the movable contact (with the white wire attached) on the forward and reverse rotor (Figure 11-13, Page 11-13). The reading should be continuity. Page 11-12 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement...
  • Page 25 REVERSE ROTOR REVERSE TERMINAL LUG 6-GAUGE GREEN WIRE FORWARD WHITE WIRE TERMINAL TERMINAL LUG OF FORWARD AND 18-GAUGE REVERSE ROTOR RED WIRE 6-GAUGE RED WIRE Figure 11-15 Forward/Reverse Switch 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement Page 11-13...
  • Page 26 Ω 200k Ω Ω 200nA Ω 1000 --- 200nA FUSED 750V 1000 --- FUSED 750V FORWARD/REVERSE SWITCH Figure 11-16 Motor Test – Armature Figure 11-17 Motor Test – Stator Page 11-14 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement...
  • Page 27 1. If the battery cables were disconnected, reconnect them, positive cable first. Tighten terminal hardware to 110 in-lb (12.4 N·m). See preceding DANGER. 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement Page 11-15...
  • Page 28 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 contacts. There should be sufficient spring pressure in the arm to keep the wiper arm brush firmly against each of the fixed contacts as it travels across them.
  • Page 29 ELECTRICAL SYSTEM AND TESTING Test Procedures 3. Make sure all the contacts are tight and the V-Glide wiper switch housing is not melted or burned around the contacts. If the housing or fixed contacts are damaged, the entire wiper switch housing with contacts must be replaced.

  • Page 31: Section 12 - Electrical Components

    2.3. Insert screwdriver at the top center of the dash between dash and cowl brace. Gently pry center dash out slightly from under edge of cowl brace. Figure 12-1 Dash Removal 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement Page 12-1...
  • Page 32 4. 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. Figure 12-2 Key Switch Page 12-2 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement...

  • Page 33: Forward/Reverse Anti-Arcing Limit Switch

    Figure 12-3 Forward/Reverse Anti-arcing Limit Switch ACCELERATOR PEDAL LIMIT SWITCH See General Warning, Section 10, Page 10-1. Testing the Accelerator Pedal Limit Switch See Test Procedure 4, Section 11, Page 11-9. 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement Page 12-3...

  • Page 34: Reverse Buzzer

    2. Remove no. 5 and no. 6 batteries from vehicle. See Figure 10-1, Section 10, Page 10-2. 3. Remove the cover (10) from the V-Glide wiper switch housing (1) (Figure 12-9, Page 12-10). 4. Disconnect the accelerator rod from the ball stud (5) on the wiper switch.

  • Page 35: Solenoid

    100 in-lb (11.3 N·m). Tighten the outer nuts of the small solenoid posts to 4 in-lb (0.5 N·m) (Figure 12-5, Page 12-6). See following WARNING. 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement Page 12-5...

  • Page 36: Resistors

    2. Loosen, but do not remove, the nuts (1) that secure the resistors (R1 through R5) to the mounting board and then slide the resistors out from under the washers (3) (Figure 12-6, Page 12-7). Page 12-6 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement...
  • Page 37 • 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 replaced with new coils (CCI P/N 1014654 and 1014655).

  • Page 38: Wiper Switch

    See General Warning, Section 10, Page 10-1. The V-Glide wiper switch is located in the battery compartment next to battery no. 6. The wiper switch arm adjustment should be checked if the brush on the V-Glide wiper switch is replaced. The pedal group adjust- ments should to be checked if any of the pedal group or the accelerator rod has been adjusted, removed, or replaced.
  • Page 39 5. Proceed to Wiper Switch Adjustment. Wiper Switch Adjustment Each of the adjustments listed in the following WARNING affects V-Glide wiper switch adjustment. To ensure proper vehicle operation, if any one item requires adjustment, all must be checked, and adjusted if necessary, in the order listed.
  • Page 40 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).
  • Page 41 1. Install bearings (8) into the wiper switch housing by lightly tapping them with a plastic hammer. Make sure that the collars of the bearings are flush against the wiper switch housing (Figure 12-9, Page 12-10). 2. With the spring (13) in place, hold the V-Glide wiper switch arm shaft (17) and carrier (12) together. See following CAUTION.
  • Page 42 fixed contacts must be replaced. 1. Position shim plate (29) on I-beam and then place V-Glide wiper switch assembly in position on shim plate. Install mounting bolts (26), lock washers (27), and nuts (28) (Figure 12-9, Page 12-10). Make sure square shoulders on the bolts fit squarely into the wiper switch housing.
  • Page 43 N·m). See following WARNING and CAUTION. ∆ WARNING • Make sure wires are connected to V-Glide wiper switch contacts exactly as stated. If they are not, the vehicle could start in a speed other than first. CAUTION • Do not operate vehicle without V-Glide wiper switch cover in place. Operating vehicle without the cover allows dirt, dust, and water to contaminate wiper switch, which could cause switch to fail or malfunction.

  • Page 44: Forward/Reverse Switch

    3 PLACES BLUE WIRE BROWN WIRE YELLOW WIRE PURPLE WIRE GREEN WIRE WHITE WIRE TYPICAL 3 PLACES 6-GAUGE 18-GAUGE RED WIRE RED WIRE TYPICAL 3 PLACES Figure 12-11 Forward/Reverse Switch Page 12-14 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement...

  • Page 45: Charger Receptacle

    DC cord removal and installation. See following NOTE. NOTE: If the warning tag has been damaged or removed from the DC cord, have it replaced immediately. 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement Page 12-15...
  • Page 46 4. Remove screws (3 and 18) attaching receptacle to the fuse link bracket (4). VEHICLE TYPICAL BODY 2 PLACES TYPICAL 2 PLACES TYPICAL TYPICAL 2 PLACES 4 PLACES TYPICAL 2 PLACES TYPICAL 2 PLACES Figure 12-12 Receptacle Page 12-16 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement...

  • Page 47: Receptacle Fuse Link

    (19) and nut (20). Tighten the nut to 23 in-lb (2.5 N·m). 5. Install fuse link assembly and cover (6). Tighten screws (5) to 20 in-lb (2.2 N·m). 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement Page 12-17...

  • Page 49: Section 13 - Batteries

    The outward appearances of these two types of batteries are similar, but the operating characteristics are very different. The Club Car electric vehicle battery is a deep-cycle battery, and the automotive battery is a “start- ing, lighting and ignition” (SLI) battery. They should never be substituted for one another.
  • Page 50 The result is a charged battery that is again capable of generating electricity (Figure 13-1, Page 13-2). CHARGER PbSO 4 PbSO Figure 13-3 Discharged Battery Figure 13-4 Battery Charging Page 13-2 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement...

  • Page 51: Common Misconceptions About Batteries

    Section 10, Page 10-1. Remove remaining wires and batteries. See Wiring Diagram, Section 11, Page 11-4. 2. Visually inspect the new batteries for any damage that may have occurred in transit. 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement Page 13-3...

  • Page 52: Battery Care

    Any frayed or worn wires should be replaced. After all cables have been con- nected, coat all terminals with Battery Terminal Protector Spray (CCI P/N 1014305) to help prevent future corrosion. Page 13-4 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement...

  • Page 53: Self-Discharge

    This reduces the battery’s capacity and corrodes the metal parts around it. 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement Page 13-5...

  • Page 54: Vibration Damage

    BATTERY CHARGING See General Warning, Section 10, Page 10-1. The charger supplied with the Club Car electric vehicle resolves the most common problems associated with battery charging. Undercharging and overcharging are prevented provided the charger is allowed to shut off by itself.

  • Page 55: Charger Does Not Shut Off Automatically

    The deeper the discharge, the harder it is on the batteries. For this reason, it is recommended that Club Car electric vehicle batteries be charged after each use (pro- vided the charge cycle will not be interrupted and the charger will be allowed to shut off automatically). Placing the batteries on charge after each use reduces the depth of discharge and prolongs battery life.

  • Page 56: Battery Troubleshooting Chart

    If discharge time is 60 minutes or If discharge time is less than 60 minutes, more, problem is not with the batteries. replace all batteries below 5.0 volts. Figure 13-7 Battery Troubleshooting Chart Page 13-8 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement...

  • Page 57: Battery Testing

    4. When the float rises off the bottom, adjust the electrolyte level so that the float rides free of the bottom but does not strike the top of the glass tube. Remove the hydrometer from the cell and release the pres- sure from the bulb. 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement Page 13-9...
  • Page 58 If the difference between the cells is 0.020 or more, the low cell should be suspected. It may require a catch- up charge or it may be a weak cell. When the variations between cells reach 0.050 or more, the battery with the low cell should be replaced. Page 13-10 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement...

  • Page 59: Discharge Test

    2. Connect the tester probes to the positive (+) post of battery no.1 and negative (–) post of battery no. 6 (Figure 13-9, Page 13-11). FRONT OF VEHICLE TESTER Figure 13-9 Battery Discharge Test 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement Page 13-11...
  • Page 60 120-129 °F 57 Minutes 72 Minutes (21-23 °C) (49-54 °C) 75-79 °F 130-150 °F 60 Minutes 74 Minutes (24-26 °C) (54-66 °C) 80-84 °F 62 Minutes ***** ***** (27-29 °C) Page 13-12 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement...

  • Page 61: Battery Troubleshooting Examples

    (–) post cell was completely dead. Battery no. 2 should be replaced with a battery that has the same age and usage as the other batteries in the set. 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement Page 13-13...

  • Page 62: Battery Storage

    60 °F (15.6 °C) prior to charge. Batteries do not charge effectively in cold temperatures for the same rea- sons they do not discharge as rapidly in cold temperatures. CHARGING A BATTERY PACK THAT HAS LOW VOLTAGE See the appropriate battery charger maintenance and service manual. Page 13-14 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement...

  • Page 63: Section 14 - Battery Charger

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

  • Page 65: Section 15 - Motor

    • See General Warning, Section 10, Page 10-1. GENERAL INFORMATION All DS V-Glide electric vehicles are equipped with 36-volt DC, series wound, reversible traction motors. If the motor should require major repair, it should be sent to a qualified motor repair shop; however, there are many minor repairs that can be made by a trained technician.
  • Page 66 field coil or bad connections at the terminals 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. Page 15-2 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement...

  • Page 67: Motor

    (pushing upwards) to move it out of the way (Figure 15-4, Page 15-4). 7. Remove the nuts and bolts mounting the rear leaf springs to the shackles. 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement Page 15-3...
  • Page 68 8. To remove brush springs (14) from rigging, lift the spring extensions out and over the brush mounts and then slide the springs off their mounting tabs (Figure 15-6, Page 15-5). Page 15-4 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement...

  • Page 69: Motor Component Testing And Inspection

    • Flared armature windings • Damaged armature core laminations • Worn, burned or glazed commutators • Dirty or oily commutators • Raised commutator bars • Worn armature bearing or shaft 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement Page 15-5...

  • Page 70: Field Windings Inspection

    Burned or scorched insulation on the field windings indicates the motor has overheated due to overloads or grounded or shorted coil windings. If the insulation on the field windings is scorched, replace the motor or the stator shell assembly. Page 15-6 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement...

  • Page 71: Motor Components

    Do not remove the bearing from the armature shaft unless it is to be replaced. Figure 15-8 Brush Spring Tension Test Figure 15-9 Bearing Inspection 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement Page 15-7...
  • Page 72 MOTOR Motor Component Testing and Inspection TYPICAL 2 PLACES TYPICAL 2 PLACES TYPICAL 4 PLACES TYPICAL 3 PLACES Figure 15-10 Motor Page 15-8 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement...

  • Page 73: Bearing Removal

    See General Warning, Section 10, Page 10-1. Motor reconditioning must be performed by a qualified motor repair technician. The use of proper tools and procedures is absolutely essential for successful motor reconditioning. 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement Page 15-9...

  • Page 74: Motor Assembly

    Release the brushes and place the springs outside the brushes so the brushes are being held against the commutator. See following CAUTION. Page 15-10 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement...

  • Page 75: Motor Installation

    1.2. Wipe input shaft with a clean cloth. 1.3. Inspect the grooves of the input shaft and remove any remaining debris. 1.4. Repeat steps 1.1 through 1.3 until input shaft is clean. 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement Page 15-11...
  • Page 76 (Figure 15-10, Page 15-8). There will be approximately 1/16 inch (1.6 mm) gap between the motor adapter ring and transaxle housing as shown (Figure 15-17, Page 15-13). Page 15-12 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement...
  • Page 77 4.8. Install the motor wires, making sure they are connected to the correct motor terminals and that the terminal orientation is correct. See Wiring Diagram, Section 11, Page 11-4. Tighten the terminal retaining nuts to 65 in-lb (7.3 N·m). 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement Page 15-13...
  • Page 78 REVERSE position. The reverse buzzer will sound as a warning when the Forward/Reverse switch is in REVERSE. 11.3. Make sure that the vehicle does not operate when the Forward/Reverse switch is in the NEUTRAL position. Page 15-14 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement...

  • Page 79: Section 16A - Transaxle (Type G)

    • See General Warning, Section 10, Page 10-1. TRANSAXLE IDENTIFICATION Club Car electric vehicles utilize one of two types of transaxles. The different transaxles are identified by the orientation of the gear case bolt heads: • The Type G transaxle has gear case bolt heads oriented toward the passenger side of the vehicle.
  • Page 80 Figure 16a-1 Axle Tube Figure 16a-2 Axle Seal and Adapter Ring Removal ADAPTER RING LIP Figure 16a-3 Axle Seal and Adapter Ring Figure 16a-4 Axle Seal and Adapter Ring Installation Page 16a-2 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement...
  • Page 81 TRANSAXLE (TYPE G) Axle Bearing and Shaft Figure 16a-5 Transaxle – Type G 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement Page 16a-3...

  • Page 82: Axle Bearing

    Do not remove the axle bearing (5) from a Type G transaxle. If bearing is worn or damaged, the entire axle assembly (1 or 2) must be replaced (Figure 16a-5, Page 16a-3). TRANSAXLE See General Warning, Section 10, Page 10-1. Page 16a-4 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement...

  • Page 83: Transaxle Removal

    7. With a floor jack supporting the transaxle, remove lower spring shackle nuts and bolts. Position shackles so they are clear of springs (Figure 16a-9, Page 16a-5). Remove bolts, then rotate shackles up and away from spring. Figure 16a-8 Disconnect Shocks Figure 16a-9 Shackles 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement Page 16a-5...
  • Page 84 NOTE: Recycle or dispose of used oil or lubricant in accordance with local, state, and federal regulations. 15. Remove the brake assemblies if required. See Section 6 – Wheel Brake Assemblies in the appropri- ate maintenance and service manual. Page 16a-6 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement...

  • Page 85: Transaxle Disassembly, Inspection, And Assembly

    • Do not reuse bearings after removing them. Replace bearings with new ones. 6. To disassemble the intermediate gear assembly, press off together the bearing (16) and the gear (19) (Figure 16a-5, Page 16a-3). See also Figure 16a-13, Page 16a-8. 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement Page 16a-7...
  • Page 86 8.4. Remove the differential pin (31) by pushing pin through differential gear case from one side (Figure 16a-5, Page 16a-3). See also Figure 16a-15, Page 16a-9. 8.5. Remove the idler gears and thrust plates (1 and 2) (Figure 16a-16, Page 16a-9). Page 16a-8 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement...

  • Page 87: Transaxle Assembly

    6. Install the differential assembly, the intermediate gear assembly, and the input pinion gear simulta- neously. Be sure all bearings are seated properly in the housing. Rotate the input shaft to check for smooth gear operation (Figure 16a-11, Page 16a-6). 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement Page 16a-9...

  • Page 88: Transaxle Installation

    25 ft-lb (34 N·m). Tighten the U-bolt nuts so an equal amount of thread is visible on each leg of the bolt. 4. Install the motor. See Section 15 – Motor. Page 16a-10 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement...
  • Page 89 11. Lift the vehicle and remove the jack stands. 12. Lower vehicle and tighten the lug nuts, using a crisscross pattern, to 55 ft-lb (74.6 N·m). 13. Test drive the vehicle to check for proper operation. 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement Page 16a-11...

  • Page 91: Section 16B - Transaxle (Type K)

    • See General Warning, Section 10, Page 10-1. TRANSAXLE IDENTIFICATION Club Car electric vehicles utilize one of two types of transaxles. The different transaxles are identified by the orientation of the gear case bolt heads: • The Type G transaxle has gear case bolt heads oriented toward the passenger-side of the vehicle.
  • Page 92 7. Inspect bearing (5) (Figure 16b-4, Page 16b-3). If the bearing is worn or damaged, replace it. Figure 16b-1 Axle Tube Figure 16b-2 Rolling Wedge Bar Figure 16b-3 Seal Lip Page 16b-2 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement...
  • Page 93 TRANSAXLE (TYPE K) Axle Bearing and Shaft Figure 16b-4 Transaxle – Type K 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement Page 16b-3...

  • Page 94: Axle Bearing

    • The collar should be removed no more than two times. If a bearing is removed a third time, the shaft and collar will not give a proper fit. 3. Place the bearing and the collar on the shaft (note, this is a sealed bearing). See following CAUTION. Page 16b-4 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement...

  • Page 95: Transaxle

    Loss of vehicle control could result, causing severe personal injury. TRANSAXLE See General Warning, Section 10, Page 10-1. TRANSAXLE REMOVAL 1. Place chocks at the front wheels and slightly loosen lug nuts on both rear wheels. 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement Page 16b-5...
  • Page 96 7. With a floor jack supporting the transaxle, remove lower spring shackle nuts and bolts. Position shackles so they are clear of springs (Figure 16b-10, Page 16b-6). Remove bolts, then rotate shackles up and away from spring. Figure 16b-9 Disconnect Shocks Figure 16b-10 Shackles Page 16b-6 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement...
  • Page 97 NOTE: Recycle or dispose of used oil or lubricant in accordance with local, state, and federal regulations. 15. Remove the brake assemblies if required. See Section 6 – Wheel Brake Assemblies in the appropri- ate maintenance and service manual. 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement Page 16b-7...

  • Page 98: Transaxle Disassembly, Inspection, And Assembly

    (Figure 16b-4, Page 16b-3). See also Figure 16b-14, Page 16b-9. See follow- ing CAUTION. CAUTION • Do not reuse bearings after removing them. Replace bearings with new ones. Page 16b-8 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement...
  • Page 99 9.2) into the differential gear unit and, while holding the unit slightly above the work area, lightly tap the bolt heads (Figure 16b-17, Page 16b-9). Remove the two bolts. DOWEL PIN LOCK PLATE Figure 16b-16 Lock Plate Figure 16b-17 Separate Housing 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement Page 16b-9...

  • Page 100: Transaxle Assembly

    2.2. While aligning the dowel pin, assemble the two halves of the differential gear case (33 and 36) and reinstall the output gear (30) (Figure 16b-4, Page 16b-3). Page 16b-10 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement...
  • Page 101 • 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 control could result, causing severe personal injury. 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement Page 16b-11...

  • Page 102: Shimming The Transaxle

    N 1013781) should be used. SHIMS SEAL SURFACE MEASUREMENT REQUIRED Up to 0.134 in. (3.4 mm) 0.134 -0.142 in. (3.4-3.6 mm) 0.142 -0.150 in. (3.6-3.8 mm) 0.150 -0.155 in. (3.8-3.9 mm) Page 16b-12 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement...

  • Page 103: Transaxle Installation

    11. Lift the vehicle and remove the jack stands. 12. Lower vehicle and tighten the lug nuts, using a crisscross pattern, to 55 ft-lb (74.6 N·m). 13. Test drive the vehicle to check for proper operation. 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement Page 16b-13...
  • Page 105 ........15-6 bearing, motor bearing ............15-7 see motor field windings ..........15-6 brush, wiper switch motor components ........15-7 see wiper switch transaxle, type g ..........16a-7 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement Page i-1...
  • Page 106 ...........16a-1 inspection ............16a-7 receptacle installation ............16a-10 see charger receptacle lubrication ............16a-1 resistor oil seal installation ............12-7 installation ..........16a-4 removal ............12-6 removal .............16a-1 testing ............11-11 removal ............16a-5 Page i-2 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement...
  • Page 107 ............12-8 adjustment ............12-9 arm adjustment ..........12-8 assembly ............12-11 brush replacement ........12-10 disassembly ..........12-11 installation ............. 12-12 removal ............12-11 testing ............11-16 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement Page i-3...
  • Page 109 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement...
  • Page 112 Golf Cars and Utility Vehicles Club Car Inc. P.O. Box 204658 Augusta, GA 30917-4658...

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