Home
Club Car
Electric Vehicles
DS Villager 4 2006
Club Car DS Villager 4 2006 Maintenance And Service Manual Supplement
4
of 1
of 1 rating
176 pages
Give review
Manual
Specs
To Next Page
To Next Page
Loading...
Manual Number 103373106
Edition Code 1007D1210C
DS V
illager 4, Carryall 1, T
urf 1
IQ System Electric V
ehicles
2008-201
1 IQ System
Maintenance and Service
Manual Supplement
2
Table of Contents
Default Chapter
5
Table of Contents
5
Section 10 - Periodic Maintenance
9
General Warning
9
Disabling the Vehicle
10
Disconnecting the Batteries
11
Connecting the Batteries
11
General Information
12
Periodic Service Schedule
12
Periodic Lubrication Schedule
14
Section 11 - Electrical System and Testing
15
General Information
15
Wiring Diagrams
16
Troubleshooting
24
Troubleshooting the Vehicle with the IQDM
24
Troubleshooting Guide 1
25
Troubleshooting Guide 2
28
Test Procedures
30
Index of Test Procedures
30
Communication Display Module (CDM)
55
Using the CDM to Retrieve Data from the Onboard Computer
56
CDM Troubleshooting Guide
57
Section 12 - Iq Display Module (Iqdm) Series 2 and Iqdm-P Diagnostics
59
Plugging the Handset into the Vehicle
59
Introductory Display
60
Menu Navigation
60
Monitor Menu
62
Faults Menu
64
Functions Menu
69
Get Settings from Controller
69
Write Settings to Controller
70
Reset All Settings
71
Information
72
Programmer Setup
72
Program
72
Faults
72
Information
73
IQDM and IQDM-P Handset Troubleshooting
73
Test Procedures
75
Index of Test Procedures
75
Section 13 - Electrical Components
79
Key Switch
79
Forward/Reverse Rocker Switch
81
Tow/Run Switch
83
Motor Controller Output Regulator (MCOR)
83
Reverse Buzzer
85
Solenoid
85
Onboard Computer (OBC)
87
Solid State Speed Controller
89
Charger Receptacle
91
Receptacle Fuse Link
92
Battery Warning Light
93
Pin 9 Diode
93
Ferrite Beads - CE Mark Vehicles
95
2008-2010 Model Years
95
Starting 2011 Model Year
96
Section 14 - Batteries
97
General Information
97
Battery Care
97
Preventive Maintenance
97
Self-Discharge
97
Electrolyte Level
98
Water Quality
98
Vibration Damage
99
Battery Charging
100
Charger Shuts off after 16 Hours
100
Deep-Discharge
100
Early Excessive Discharging
100
Incoming AC Service
101
Fleet Rotation
101
Numbering Vehicles and Chargers
101
Battery Troubleshooting Chart
102
Battery Testing - 8 Volt
103
Battery Charger Test
103
On-Charge Voltage Test
103
Hydrometer Test
103
Discharge Test
105
Battery Troubleshooting Examples
107
Battery Testing - 12 Volt
108
Battery Charger Test
108
On-Charge Voltage Test
108
Hydrometer Test
108
Discharge Test
110
Battery Troubleshooting Examples
112
Battery Storage
113
Battery Replacement
113
Charging a Battery Pack that Has Low Voltage
115
Section 15 - Battery Charger
117
Refer to the Appropriate Battery Charger Maintenance and Service Manual
117
Section 16A - Motor (Model 5Bc59Jbs6390)
119
General Information
119
Motor Identification
119
External Motor Testing
119
Motor
120
Motor Component Testing and Inspection
123
Armature
123
Field Windings Inspection
124
Motor Components
124
Bearing Inspection
125
Bearing Removal
125
Bearing Installation
125
Speed Sensor Magnet Inspection
127
Speed Sensor Magnet Removal
127
Speed Sensor Magnet Installation
127
Reconditioning the Motor
127
Motor Assembly
128
Motor Installation
130
Motor Speed Sensor
133
Section 16B - Motor (Models Ej4-4001 and Ej8-4001A)
135
General Information
135
Motor Identification
135
External Motor Testing
135
Motor
137
Motor Removal
137
Motor Disassembly
139
Motor Component Testing and Inspection
141
Armature Inspection and Testing
141
Motor Frame and Field Windings Inspection
142
Motor Brush, Spring, and Terminal Insulator Inspection
142
Reconditioning the Motor
146
Motor Assembly
146
Motor Installation
148
Section 17 - Transaxle (Type G)
151
Lubrication
151
Axle Bearing and Shaft
151
Axle Shaft
151
Axle Bearing
154
Transaxle
155
Transaxle Removal
155
Transaxle Disassembly, Inspection, and Assembly
157
Transaxle Disassembly and Inspection
157
Transaxle Assembly
159
Transaxle Installation
160
Section 18 - Iq Display Module (Iqdm-P) Programming
163
Plugging the Handset into the Vehicle
163
Program Menu
164
Speed Setting
164
Fast Accel
165
Pedal up Mode
165
Speed Cal
165
Code A, Code B, and Code C
165
Other manuals for Club Car DS Villager 4 2006
Owner's Manual
80 pages
4
Based on 1 rating
Ask a question
Give review
Questions and Answers:
Need help?
Do you have a question about the Club Car DS Villager 4 2006 and is the answer not in the manual?
Ask a question
Club Car DS Villager 4 2006 Specifications
General
Brand
Club Car
Model
DS Villager 4 2006
Category
Electric Vehicles
Language
English
Related product manuals
Club Car DS Villager 4
80 pages
Club Car Tempo 2020
684 pages
Club Car Carryall I 2000
44 pages
Club Car TransPorter 4
80 pages
Club Car TransPorter 6
80 pages
Need help?
General
To Next Page
