Charger Receptacle - Club Car V-GLIDE Maintenance Service Supplement

ELECTRICAL COMPONENTS
Forward/Reverse Switch Removal
1. Disconnect the battery cables as instructed. See WARNING "To avoid unintentionally starting..." in
General Warning, Section 10, Page 10-1.
2. Remove Forward/Reverse handle mounting screw (3) and handle (2) (Figure 12-11, Page 12-14).
3. Disconnect the wires from the Forward/Reverse switch.
4. Remove the screws (4), washers (9) and nuts (5) that mount Forward/Reverse switch to the body
(Figure 12-11, Page 12-14).
5. Remove Forward/Reverse switch.
Forward/Reverse Switch Installation
1. Connect the wires to the terminal lugs of the Forward/Reverse switch as shown (Figure 12-11,
Page 12-14). Tighten the nuts to 45 in-lb (5.1 N·m). See following NOTE.
NOTE: Make sure the 6-gauge red and green wires are angled 45° toward the passenger side of the vehi-
cle as shown (Figure 12-11, Page 12-14).
2. Secure the Forward/Reverse switch to rear body. Tighten hardware to 33 in-lb (3.3 N·m) (Figure 12-11,
Page 12-14).
3. Connect the two 6-gauge wires to the movable contact on the back of the Forward/Reverse switch.
Tighten bolts to 27 in-lb (3.0 N·m) (Figure 12-11, Page 12-14). See following NOTE.
NOTE: Use a 7/16-inch wrench to prevent movable contact 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 12-14).
6. 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.

CHARGER RECEPTACLE

See General Warning, Section 10, Page 10-1.
The charger cord, plug, and receptacle are wear items and should be inspected daily. Visually inspect them
for cracks, loose connections, and frayed wiring; they must be replaced when worn or damaged. If charger
plug or receptacle show signs of corrosion or the plug is difficult to insert or remove, the receptacle contacts
and plug terminals should be cleaned with a good electrical contact cleaner or lightly sprayed with WD-40
brand spray lubricant. The plug should then be inserted and removed several times to ensure ease of inser-
tion, ease of removal, and good electrical contact. See DC Cord in the appropriate battery charger main-
tenance and service manual for 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
12
Charger Receptacle
®
Page 12-15