Name: Club Car Precedent Villager 2 2019
Brand: Club Car
Rating: 4 (1 reviews)

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2019Precedent,

Villager2and4

Maintenanceand

ServiceManual

ElectricVehiclewithERICChargingSystem

GasolineVehiclewithKohlerECH440Engine

ManualNumber86753090002

EditionCodeB

Table of Contents7
SECTION 1 - Safety19
Safety Details19
General Warnings20
Disabling the Vehicle21
Disconnect the Battery - Gasoline Vehicles21
Connect the Battery - Gasoline Vehicles22
Disconnect the Batteries - Electric Vehicles22
Connect the Batteries - Electric Vehicles23
Recycling Lead-Acid Batteries24
International Safety Symbols on Batteries24
SECTION 2 - Vehicle Specifications25
Electric - Vehicle Specifications25
Dimensions25
Performance25
Tires25
Electric Motor25
Batteries26
Noise and Vibration26
Transaxle26
Vehicle Weights and Load Capacities26
Gasoline - Vehicle Specifications27
Dimensions27
Performance28
Tires28
Gasoline Engine28
Battery28
Noise and Vibration28
Transaxle28
Vehicle Weights and Load Capacities29
SECTION 3 - Extended Storage31
Electric Vehicle Extended Storage31
Extended Storage Preparation - Electric31
Return to Service from Extended Storage - Electric32
Gasoline Vehicle Extended Storage34
Extended Storage Preparation - Gasoline34
Return to Service from Extended Storage - Gasoline35
SECTION 4 - Body and Trim37
Cleaning the Windshield37
Cleaning the Vehicle Exterior37
Cleaning the Vehicle Interior38
Body Repair38
Stress Lines or Streaks38
Minor Impact Damage/Deformations38
Minor Scratches and Surface Blemishes39
Gouges, Punctures, Tears, Large Scratches, and Abrasions39
Seat Hinge40
Seat Hinge Removal40
Seat Hinge Installation40
Hip Restraint41
Hip Restraint Removal41
Hip Restraint Installation41
Front Body41
Front Body Removal41
Front Body Installation42
Front Bumper44
Headlight Adjustment45
Aiming the Headlight Beam45
Instrument Panel46
Instrument Panel Removal46
Instrument Panel Installation46
Dash Assembly47
Dash Assembly Removal47
Dash Assembly Installation47
Floor Mat and Retainers48
Floor Mat Removal48
Floor Mat Installation48
Floor Mat Retainer Removal48
Floor Mat Retainer Installation48
Kick Plate and Charger Receptacle Bezel - Electric Vehicles50
Kick Plate and Charger Receptacle Bezel Removal50
Kick Plate and Charger Receptacle Bezel Installation51
Kick Plate - Gasoline Vehicles52
Kick Plate Removal52
Kick Plate Installation52
Access Panel53
Access Panel Removal53
Access Panel Installation53
Visage Display Unit Overhead Baskets54
Overhead Basket Removal54
Overhead Basket Installation54
Overhead Speaker Basket Removal55
Overhead Speaker Basket Installation55
Two-Passenger - Canopy56
Two-Passenger Canopy Removal56
Two-Passenger Canopy Installation57
Two-Passenger Canopy with Visage Display Unit Removal57
Two-Passenger Canopy with Visage Display Unit Installation59
Two-Passenger Front Canopy Strut Removal61
Two-Passenger Front Canopy Strut Installation62
Two-Passenger Rear Canopy Support Removal63
Two-Passenger Rear Canopy Support Installation64
Two-Passenger - Rear Body64
Universal Accessory Mounting64
Structural Accessory Module (SAM)65
Seat Back66
Bag Rack Assembly67
Bag Strap68
Sweater Basket69
Rear Beauty Panel70
Rear Underbody71
Rear Crossmember72
Villager 4 - Monsoon Canopy73
Monsoon Canopy Removal73
Monsoon Canopy Installation74
2+2 Front Canopy Strut Removal75
2+2 Front Canopy Strut Installation76
2+2 Rear Canopy Support Removal77
2+2 Rear Canopy Support Installation78
Villager 4 - Rear Body79
Seat Backs79
Fixed Rear Seat81
Fold-Down Rear Seat84
Seat Support88
Foot Deck - 2+289
Rear Beauty Panel (2+2 Vehicles)93
Rear Underbody94
SECTION 5 - Accelerator and Brake Pedal Group95
Pedal Group - Electric Vehicle95
Pedal Group Removal95
Mcor97
Pedal Group Installation97
Pedal Group - Gasoline Vehicle98
Pedal Group Removal98
Throttle Position Sensor99
Pedal Group Installation100
Debris Shields100
Accelerator Pedal Removal100
Accelerator Pedal Installation100
Brake Pedal Removal101
Brake Pedal Installation101
SECTION 6 - Wheel Brake Assemblies103
General Information103
Brake Shoe Removal105
Brake Assembly Cleaning107
Brake Shoe Installation110
Brake Cable Equalizer Adjustment114
Brake Cluster115
Brake Cluster Removal115
Brake Cluster Installation117
Brake Cable119
Brake Cable Removal119
Brake Cable Installation122
SECTION 7 - Steering and Front Suspension125
General Information125
Steering Wheel125
Steering Wheel Removal125
Steering Wheel Installation126
Steering Column128
Steering Column Removal128
Steering Column Installation129
Rack and Pinion130
Rack and Pinion Inspection130
Rack and Pinion Removal130
Rack and Pinion Installation131
Front Suspension133
Lubrication133
Wheel Alignment133
Front Suspension Components136
Tie Rod End Removal136
Tie Rod Installation136
Leaf Spring Removal137
Leaf Spring Installation138
Kingpin and Steering Spindle Removal139
Kingpin and Steering Spindle Installation140
Control Arm Removal141
Control Arm Installation142
Front Shock Absorber Inspection143
Front Shock Absorber Removal144
Front Shock Absorber Installation144
Front Wheel Hubs146
Front Wheel Free Play Inspection146
Front Wheel Hub Removal146
Front Wheel Hub Installation147
SECTION 8 - Wheels and Tires149
General Information149
Wheels149
Wheel Removal149
Wheel Installation149
Tires150
Tire Removal150
Tire Repair150
Tire Installation151
SECTION 9 - Rear Suspension153
General Information153
Shock Absorbers153
Rear Shock Absorber Inspection153
Rear Shock Absorber Removal154
Rear Shock Absorber Installation155
Panhard and Bracket156
Panhard and Bracket Removal156
Panhard and Bracket Installation156
Leaf Springs (Two-Passenger)157
Leaf Spring Removal (Two-Passenger)157
Leaf Spring Installation (Two-Passenger)159
Leaf Springs (Four-Passenger)160
Leaf Spring Removal (Four-Passenger)160
Leaf Spring Installation (Four-Passenger)162
Leaf Springs (Four-Passenger - Heavy Duty with Panhard)163
Leaf Spring Removal (Four-Passenger - Heavy Duty with Panhard)163
Leaf Spring Installation (Four-Passenger - Heavy Duty with Panhard)165
SECTION 10 - Periodic Maintenance167
General Information167
Pre-Operation and Daily Safety Checklist167
Performance Inspection168
Maintenance169
Periodic Service Schedules170
Periodic Lubrication Schedules174
Air Filter176
Air Filter Removal176
Air Filter Installation176
Engine Oil176
Engine Oil Viscosity176
Engine Oil Level Inspection177
Engine Oil Replacement178
Add Engine Oil180
SECTION 11 - Controller Diagnostic Tool (CDT)183
General Information184
Features184
Plugging the CDT into the Vehicle185
Introductory Display185
Quick Reference Guide - Excel with ERIC Charging System186
System Info187
Model Number187
Serial Number187
Hardware Version187
Protocol Version187
Param Block Version187
MFG Date Code187
OS Version187
SM Version187
VCL App Version187
Parameters188
Settings188
Amp Hours190
Access Codes190
Vehicle ID191
Monitor Menu191
Batt Voltage192
Min I192
Signed Battery Current192
BDI Percent192
Speed192
Throttle192
Temperature192
Arm Current192
Field Current192
Armature PWM193
Field PWM193
Speed Pulses193
Foot Input193
Key Input193
Forward Input193
Reverse Input193
Mode Switch Input193
Charger Inhibit193
Main Cont Driver193
Password Tries (OEM Access Level Only)194
Odometer194
BDI Info194
Battery Monitor194
Charging Totals194
Amp Hours Display195
Lin195
Vehicle Speeds195
Pedal Counters195
Fault Counters195
Fault Count Odometers195
Diagnostics Menu196
Present Errors Folder196
Fault History Folder196
Causes of Faults197
Fault Recovery199
Fault Descriptions200
Incorrect Password (OEM Access Level Only)200
Max Password Tries (OEM Access Level Only)200
Throttle Fault200
Low Battery Voltage (Undervoltage)200
Overvoltage200
Thermal Cutback201
Anti-Tamper Fault201
Hpd201
Main Drvr Overcurrent201
Lockout Fault201
Low SOC201
Main Welded202
High Speed Walkaway202
Speed Sensor202
Main Driver on202
Main Coil Open202
Main Dropout (1 or 2)203
Motor Stall203
Main Driver off203
Current Sense Fault203
M- Shorted203
FLD (Field) Missing204
HW Failsafe204
Fault History204
Clear Fault History204
Programming204
Cloning205
Favorites205
HHP Settings205
Plot & Log207
Plot207
Log207
CDT Troubleshooting208
Connection Tests209
SECTION 12 - Electric Vehicle - Troubleshooting and Electrical System213
General Information213
Accessories213
Charge Indicator Light213
Attributes of the Excel System213
Key Differences: Excel with ERIC Charging System Vs. Powerdrive Chargers214
Features214
Battery Wiring Diagram216
Sonic Weld, Fuse, and 10K Ohm Resistor Locations217
Troubleshooting218
Troubleshooting the Vehicle with the CDT218
Troubleshooting Guide 2221
Test Procedures224
Testing Basics224
SECTION 13 - Electric Vehicle - Electrical Components245
Key Switch245
Testing the Key Switch245
Key Switch Removal245
Key Switch Installation245
Charge Indicator Light246
Testing the Charge Indicator Light246
Charge Indicator Light Removal246
Charge Indicator Light Installation246
USB Port247
USB Port Removal247
USB Port Installation248
Forward/Reverse Rocker Switch248
Testing the Forward/Reverse Rocker Switch248
Forward/Reverse Rocker Switch Removal248
Forward/Reverse Rocker Switch Installation249
Electronics Module Cover250
Electronics Module Cover Removal250
Electronics Module Cover Installation250
Tow/Run Switch251
Testing the Tow/Run Switch251
Tow/Run Switch Removal251
Tow/Run Switch Installation251
Motor Controller Output Regulator (MCOR)252
Testing the MCOR252
MCOR Removal252
MCOR Installation252
Reverse Buzzer253
Testing the Reverse Buzzer253
Reverse Buzzer Removal253
Reverse Buzzer Installation253
Electronics Module254
Electronics Module Removal254
Electronics Module Installation255
Speed Controller256
Testing the Solid State Speed Controller256
Speed Controller Removal256
Speed Controller Installation256
Solenoid257
Testing the Solenoid257
Solenoid Removal257
Solenoid Installation258
Charger Receptacle258
Testing the Charger Receptacle258
Charger Receptacle Inspection258
Charger Receptacle Removal258
Charger Receptacle Installation259
SECTION 14 - Electric Vehicle - Batteries261
General Information261
Battery Testing Basics - 8 Volt262
Observation262
Measuring Voltage of Battery Set262
Battery Cell Numbering262
Battery Testing - 8 Volt263
Battery Regrouping263
Battery Replacement265
Battery Care266
Water Quality266
Deionizer267
Battery Care - Vehicles Equipped with the Single-Point Watering System268
Battery Care - Vehicles Without the Single-Point Watering System269
Self-Discharge269
Electrolyte Level270
Vibration Damage270
Single Point Watering System (SPWS)271
Initial Maintenance of the SPWS271
Watering Batteries with the SPWS271
Battery Storage273
Fleet Rotation273
Deep-Discharge273
Early Excessive Discharging273
SECTION 15 - Electric Vehicle - Battery Charger275
General Information276
USB Service Port277
UL and CSA Listing277
CE Compliance277
Plug and Receptacle277
Charger Power Connection Fuse278
Charger Interlock278
AC Input Voltage Detection278
Thermal Cutback278
Charge Indicator Light278
External Charger Status Indicators278
Onboard Charger Status Indicators279
Long-Term Storage280
External Charger Mounting281
AC Power Connection282
The Charge Circuit283
Charger Operation284
Charging Batteries284
Charger Maintenance287
USB Service Port Cleaning and Care287
Charger Troubleshooting288
Numbering Vehicles and Chargers288
USB Service Port288
Incoming AC Service288
Terminal Block Cover289
Resetting Power - External Charger289
Resetting Power - Onboard Charger289
External Charger Troubleshooting Indicators290
Onboard Charger Fault Codes292
Test Procedures294
External Charger Repairs297
Terminal Block Cover Removal297
Terminal Block Cover Installation298
DC Cord and Strain Relief Removal298
DC Cord and Strain Relief Installation298
Handle Removal298
Handle Installation299
Foot Removal299
Foot Installation299
Onboard Charger Repairs300
Onboard Charger Removal300
Onboard Charger Installation301
Terminal Block Cover Removal301
Terminal Block Cover Installation301
DC Cord and Strain Relief Removal302
DC Cord and Strain Relief Installation302
DC Charging Harness Removal302
DC Charging Harness Installation303
SECTION 16 - Electric Vehicle - Motor305
General Information305
External Motor Testing305
Motor308
Motor Removal308
Motor Disassembly309
Motor Component Testing and Inspection312
Armature Inspection and Testing312
Motor Frame and Field Windings Inspection314
Motor Brush, Spring, and Terminal Insulator Inspection314
Reconditioning the Motor317
Motor Specifications317
Motor Assembly317
Motor Installation319
SECTION 17 - Electric Vehicle - Transaxle323
Lubrication323
Axle Bearing and Shaft323
Axle Shaft323
Axle Bearing326
Transaxle Removal327
Transaxle Disassembly, Inspection, and Assembly329
Transaxle Disassembly and Inspection329
Transaxle Assembly331
Transaxle Installation332
SECTION 18 - Gasoline Vehicle - Troubleshooting and Electrical System335
General Information335
Accessories335
Features of the Electronic Fuel Injection (EFI) System335
Ground Locations335
Low Oil Warning Light336
Malfunction Indicator Light336
Troubleshooting Guide336
Gasoline Powertrain337
Fuse and Relay Locations339
Electrical System340
Test Procedures341
Testing Basics341
SECTION 19 - Gasoline Vehicle - Electrical Components367
Battery367
General Information367
Preventive Maintenance368
Self-Discharge368
Vibration Damage368
Battery Removal369
Charging the Battery369
Battery Installation369
Battery Storage370
Charging a Dead Battery370
Ground Cables370
Starter/Generator370
Starter/Generator Removal370
Disassembly of the Starter/Generator to Service the Brushes371
Brush Inspection and Replacement371
Brush Spring Inspection and Replacement372
Starter/Generator Assembly372
Disassembly of the Starter/Generator to Service the Armature/Commutator373
Bearing Cleaning and Inspection374
Bearing Removal375
Field Coil Assembly375
Visual Inspection of Armature375
Commutator Cleaning and Inspection376
Armature Ground Test377
Visual Inspection of Field Coils378
Starter/Generator Rework378
Starter/Generator Assembly378
Starter/Generator Installation381
Belt Tension Adjustment for EFI Engines382
Solenoid384
Solenoid Removal384
Solenoid Installation385
Voltage Regulator386
Voltage Regulator Removal386
Voltage Regulator Installation387
Engine Control Unit (ECU)387
Engine Control Unit Removal387
Engine Control Unit Installation388
Fuel Level Sending Unit388
Maintenance/Operate Switch388
Maintenance/Operate Switch Removal388
Maintenance/Operate Switch Installation389
Accelerator Pedal Limit Switch389
Kill Limit Switch390
Multi-Purpose Buzzer Limit Switch390
Multi-Purpose Buzzer Limit Switch Removal390
Multi-Purpose Buzzer Limit Switch Installation391
Neutral Lockout Limit Switch391
Neutral Lockout Limit Switch Removal391
Neutral Lockout Limit Switch Installation392
Transaxle Limit Switch393
Transaxle Limit Switch Removal393
Transaxle Limit Switch Installation393
Brake Light Relay394
Brake Light Relay Removal394
Brake Light Relay Installation395
Fuel Gauge/Hour Meter395
General Information395
Fuel Gauge/Hour Meter Removal396
Fuel Gauge/Hour Meter Installation396
Headlight Switch397
Headlight Switch Removal397
Headlight Switch Installation397
Key Switch398
Key Switch Removal398
Key Switch Installation398
Low Oil Warning Light399
Low Oil Warning Light Removal399
Low Oil Warning Light Installation399
Malfunction Indicator Light (MIL)400
Malfunction Indicator Light Removal400
Malfunction Indicator Light Installation400
Multi-Purpose Buzzer401
Multi-Purpose Buzzer Removal401
Multi-Purpose Buzzer Installation401
USB Receptacle402
USB Receptacle Removal402
USB Receptacle Installation402
Oxygen Sensor403
Oxygen Sensor Removal403
Oxygen Sensor Installation403
SECTION 20 - Gasoline Vehicle - Engine405
General Information405
Before Servicing405
Engine Removal406
Engine Installation409
Snubber412
Snubber Removal412
Snubber Installation412
SECTION 21 - Gasoline Vehicle - Fuel System413
General Information413
EFI System Features/Specifications413
Engine Control Linkages414
General Information414
Ground Speed414
Governor Cable414
Accelerator Cable417
Idle Adjustment420
How to Measure Ground Speed420
Engine RPM Adjustment421
Air Intake System422
Air Cleaner Removal422
Air Cleaner Installation422
Relieving Fuel Pressure423
To Relieve Fuel Pressure423
Carbon Canister424
Carbon Canister Removal424
Carbon Canister Installation424
Fuel Line425
Fuel Line Removal425
Fuel Line Installation427
Fuel Pump Module429
General Information429
Fuel Pump Module Removal429
Fuel Pump Module Installation431
Fuel Tank432
General Information432
Fuel Tank Removal432
Fuel Tank Disposal434
Fuel Tank Storage434
Fuel Tank Installation434
Fuel Filter436
General Information436
Fuel Filter Removal436
Fuel Filter Installation437
SECTION 22 - Gasoline Vehicle - Exhaust System439
Muffler439
Muffler Removal439
Muffler Installation440
SECTION 23 - Gasoline Vehicle - Clutches441
General Information441
Troubleshooting441
Drive Belt443
Drive Belt Removal443
Drive Belt Installation443
Drive Clutch444
Drive Clutch Removal445
Drive Clutch Cleaning and Inspection446
Drive Clutch Disassembly446
Inspection of Drive Clutch Parts449
Drive Clutch Assembly450
Drive Clutch Installation451
Driven Clutch452
Driven Clutch Removal453
Driven Clutch Disassembly453
Driven Clutch Inspection455
Driven Clutch Assembly456
Driven Clutch Installation458
SECTION 24 - Gasoline Vehicle - Transaxle459
General Information459
Shifter Lever459
Maintenance/Operate Switch459
Governor System460
Transaxle Service460
Lubrication460
Tools Required for this Section461
Rear Hubs462
Rear Hub Removal462
Rear Hub Installation462
Axle Tubes, Axle Shafts and Wheel Bearings464
Axle Tube and Axle Shaft Removal464
Axle Tube and Axle Shaft Installation465
Rear Wheel Bearing Removal465
Rear Wheel Bearing Installation465
Axle Shaft Oil Seal Removal465
Axle Shaft Oil Seal Installation466
Transaxle Removal467
Transaxle Installation470
Forward/Neutral/Reverse Handle471
Forward/Neutral/Reverse Handle Removal471
Forward/Neutral/Reverse Handle Installation471
Shifter Cable471
Shifter Cable Removal471
Shifter Cable Installation472
Shifter Cable Adjustment472
SECTION 25 - Kohler Engine Service Manual475

Club Car Precedent Villager 2 2019 User Manual

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Club Car Precedent Villager 2 2019 Specifications

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Brand	Club Car
Model	Precedent Villager 2 2019
Category	Golf Cars
Language	English