Club Car V-GLIDE Manual

Club Car
MANUAL NUMBER 102397604 
EDITION CODE 1203A00000
V-GLIDE 36-VOLT 
ELECTRIC VEHICLES
2004
MAINTENANCE
SERVICE
SUPPLEMENT

2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement Page i
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 [phone], 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.

Page ii 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement
∆
WARNING
•Read Section 1 – Safety in the DS Golf Car Maintenance and Service Manual before attempting
any service on the vehicle.
•Before servicing vehicle, read complete section(s) and any referenced information that may
be relevant to the service or repair to be performed.
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. 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 the obligation of making changes to units previously sold.
There are no warranties expressed or implied in this supplement. See the limited warranty found in
the vehicle owner’s manual or write to: Club Car, Inc., P.O. Box 204658, Augusta, GA 30917-4658,
USA, Attention: Warranty Administration.

2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement Page iii
CONTENTS
SECTION 10 – PERIODIC MAINTENANCE
General Warning ............................................................................................................................... 10-1
General Information .......................................................................................................................... 10-2
Periodic Service Schedule ................................................................................................................ 10-2
Periodic Lubrication Schedule .......................................................................................................... 10-4
SECTION 11 – ELECTRICAL SYSTEM AND TESTING
General Information .......................................................................................................................... 11-1
Electrical Circuits .............................................................................................................................. 11-1
Control Circuit ............................................................................................................................... 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
Receptacle Fuse Link ................................................................................................................... 12-17
SECTION 13 – BATTERIES
General Information .......................................................................................................................... 13-1
Common Misconceptions About Batteries ........................................................................................ 13-3
Battery Replacement ........................................................................................................................ 13-3

Page iv 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement
Battery Care ..................................................................................................................................... 13-4
Preventive Maintenance ............................................................................................................... 13-4
Self-Discharge .............................................................................................................................. 13-5
Electrolyte Level ........................................................................................................................... 13-5
Vibration Damage ........................................................................................................................ 13-6
Battery Charging .............................................................................................................................. 13-6
Charger Does Not Shut Off Automatically .................................................................................... 13-7
Deep-Discharge ........................................................................................................................... 13-7
Early Excessive Discharging ........................................................................................................ 13-7
Incoming AC Service .................................................................................................................... 13-7
Fleet Rotation ............................................................................................................................... 13-7
Numbering Vehicles and Chargers .............................................................................................. 13-7
Battery Troubleshooting Chart ......................................................................................................... 13-8
Battery Testing ................................................................................................................................. 13-9
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 Component Testing and Inspection ....................................................................................... 15-5
Armature ...................................................................................................................................... 15-5
Field Windings Inspection ............................................................................................................ 15-6
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

2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement Page v
SECTION 16A – TRANSAXLE (TYPE G)
Transaxle Identification ..................................................................................................................... 16a-1
Lubrication ........................................................................................................................................ 16a-1
Axle Bearing and Shaft ..................................................................................................................... 16a-1
Axle Shaft ..................................................................................................................................... 16a-1
Axle Bearing ................................................................................................................................. 16a-4
Transaxle .......................................................................................................................................... 16a-4
Transaxle Removal ....................................................................................................................... 16a-5
Transaxle Disassembly, Inspection, 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
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 10-1
10
SECTION 10 – PERIODIC MAINTENANCE
GENERAL WARNING
The following safety statements must be heeded whenever the vehicle is being operated, repaired, or ser-
viced. Service technicians should become familiar with these general safety statements, which can be found
throughout this manual. Also, other specific safety statements appear throughout this manual and on the vehi-
cle.
∆
DANGER
•Battery – Explosive gases! Do not smoke. Keep sparks and flames away from the vehicle and
service area. Ventilate when charging or operating vehicle in an enclosed space. Wear a full
face shield and rubber gloves when working on or near batteries.
•Battery – Poison! Contains acid! Causes severe burns. Avoid contact with skin, eyes, or
clothing. Antidotes:
- External: Flush with water. Call a physician immediately.
-Internal: Drink large quantities of milk or water. Follow with milk of magnesia or vegetable
oil. Call a physician immediately.
-Eyes: Flush with water for 15 minutes. Call a physician immediately.
∆ WARNING
•Follow the procedures exactly as stated in this manual, and heed all DANGER,WARNING, and
CAUTION statements 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 handle in the NEUTRAL position. Chock the
wheels when servicing the vehicle.
•To avoid unintentionally starting the vehicle, disconnect the batteries as shown (Figure 10-1,
Page 10-2).
•Wear safety glasses or approved eye protection when servicing the vehicle or battery charger.
Wear a full face shield and rubber gloves when working on or near batteries.
•Do not wear loose clothing or jewelry such as rings, watches, chains, etc., when servicing the
vehicle or battery charger.
•Moving parts! Do not attempt to service the vehicle while it is running.
•Hot! Do not attempt to service hot motor or resistors. Failure to heed this warning could result
in severe burns.
•Use insulated tools when working near batteries or electrical connections. Use extreme
caution to avoid shorting of components or wiring.
•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...

PERIODIC MAINTENANCE General Information
Page 10-2 2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement
10
∆
WARNING
•Any modification or change to the vehicle that affects the stability or handling of the vehicle,
or increases maximum vehicle speed beyond factory specifications, could result in severe
personal injury or death.
•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 chock the wheels that remain on the floor. When not performing a test or service
procedure that requires movement of the wheels, lock the brakes.
•If wires are removed or replaced, make sure wiring and wire harness are properly routed and
secured. Failure to properly route and secure wiring 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 established preventive maintenance
program. Regular and consistent vehicle maintenance can prevent vehicle downtime and expensive repairs that
can result from neglect. 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.
PERIODIC SERVICE SCHEDULE
∆
WARNING
•Service, repairs, and adjustments must be made per instructions in the DS Golf Car
Figure 10-1 V-Glide Battery Configuration
1
2
3
4
6
5
FRONT
OF VEHICLE
DISCONNECT
BATTERY CABLES BEFORE
WORKING ON VEHICLE