Club Car Precedent Villager 2 User Manual

2019PrecedentVillager2
Maintenanceand
ServiceManual
ElectricVehiclewithERICChargingSystem
GasolineVehiclewithSubaruEX40Engine
ManualNumber105355116
EditionCodeB

Club Car Precedent Villager 2 Specifications

General

Model	Precedent Villager 2
Seating Capacity	2
Power Source	48-volt DC (Electric)
Overall Length	91.5 inches
Ground Clearance	4.5 in (11 cm)
Power Source (Electric)	48-volt DC
Batteries	6 x 8V
Charger	Onboard
Forward Speed (Nominal)	14-19 mph
Steering	Rack and Pinion
Tires	18 x 8.5-8
Overall Width	47 in (119 cm)
Turning Radius	10 ft (305 cm)

Summary

Foreword

Section 1 - Safety

Safety Details

Details regarding safety precautions and hazard identification for vehicle operation and service.

General Warnings

General safety statements to be heeded during operation, repair, or servicing of the vehicle.

Disconnecting the Batteries – Electric Vehicles

Procedure for safely disconnecting batteries on electric models.

Section 2 - Vehicle Specifications

Vehicle Specifications – Electric and Subaru EX40

Detailed specifications for both electric and gasoline-powered models.

Section 3 - General Information

Model Identification

Explains how to identify the vehicle model using the serial number decal.

Storage – Electric Vehicle

Procedures for storing electric vehicles for extended periods.

Storage – Gasoline Vehicle

Procedures for storing gasoline vehicles for extended periods.

Section 4 - Body and Trim

Cleaning the Vehicle

Guidelines for cleaning the vehicle's body panels and seats.

Front and Rear Body Repair

Methods for repairing minor damage and deformations on the vehicle's body.

Headlight Adjustment

Procedures for adjusting and aiming the vehicle's headlights.

Instrument Panel

Steps for removing and installing the instrument panel assembly.

Section 5 - Accelerator and Brake Pedal Group

Pedal Group – Electric Vehicle

Procedures for removing the pedal group on electric vehicles.

MCOR

Information on the Motor Controller Output Regulator (MCOR) and its function.

Brake Pedal Removal

Steps for removing the brake pedal assembly.

Section 6 - Wheel Brake Assemblies

Brake Shoe Removal

Detailed steps for removing brake shoes, including asbestos dust warnings.

Brake Shoe Installation

Detailed steps for installing brake shoes correctly.

Brake Cable Equalizer Adjustment

Steps for adjusting the brake cable equalizer for proper brake tension.

Section 7 - Steering and Front Suspension

Steering Wheel

Procedures for removing and installing the steering wheel.

Rack and Pinion

Information on inspecting, removing, and installing the rack and pinion steering gear.

Front Wheel Bearings and Hubs

Procedures for inspecting, removing, and installing front wheel bearings and hubs.

Section 8 - Wheels and Tires

Wheels

Procedures for removing and installing wheels.

Tires

Procedures for removing, repairing, and installing tires.

Section 9 - Rear Suspension

Shock Absorbers

Procedures for removing and installing shock absorbers.

Leaf Springs

Procedures for removing and installing leaf springs.

Section 10 - Periodic Maintenance

Pre-Operation and Daily Safety Checklist

Daily checklist for inspecting vehicle controls, indicators, and overall condition.

Periodic Service Schedules

Schedules for regular maintenance tasks for electric and gasoline vehicles.

Periodic Lubrication Schedules

Schedules for lubrication points and recommended lubricants.

Section 11 - Controller Diagnostic Tool (CDT)

General Information

Overview of the CDT's uses for parameter adjustment, diagnostics, and monitoring.

Parameters

Details on adjusting various vehicle performance parameters using the CDT.

Monitor Menu

Accesses real-time vehicle data for troubleshooting.

DIAGNOSTICS MENU

Accesses folders for present errors and fault history.

Section 12 - Electric Vehicle - Excel System Troubleshooting

General Information

Overview of the Excel vehicle's electrical system and features.

FEATURES

Details on shunt-wound motor and motor braking features.

Troubleshooting the Vehicle with the CDT

How to use the CDT handset for troubleshooting the Excel electrical system.

Troubleshooting Guide 1

A guide intended for use with the CDT handset for diagnosing issues.

Test Procedures

Procedures for testing various electrical system components without major disassembly.

Section 13 - Electric Vehicle - Electrical Components

KEY SWITCH

Procedures for testing, removing, and installing the key switch.

MOTOR CONTROLLER OUTPUT REGULATOR (MCOR)

Procedures for testing, removing, and installing the MCOR.

SPEED CONTROLLER

Procedures for testing, removing, and installing the speed controller.

SOLENOID

Procedures for testing, removing, and installing the solenoid.

BATTERY

Information on battery testing, preventive maintenance, and storage.

Section 14 - Electric Vehicle - Batteries

Battery Testing Basics – 8 Volt

Basic observation and voltage measurement procedures for 8-volt batteries.

Battery Regrouping

Club Car's standard method for replacing batteries by grouping similar conditions.

Battery Replacement

Steps for replacing batteries, including safety warnings.

Battery Care

Guidelines for maintaining battery health and lifespan.

Deep-Discharge

Avoid discharging batteries to prevent damage and reduce cycle life.

Section 15 - Electric Vehicle - Battery Charger

General Information

Information on charger serviceability, storage features, and differences between charger types.

EXTERNAL CHARGER MOUNTING

Guidelines for securely mounting the charger for adequate ventilation.

THE CHARGE CIRCUIT

Components involved in the charge circuit: receptacle, interlock, controller, solenoid, and battery.

CHARGER OPERATION

Step-by-step procedure for charging the vehicle's batteries.

CHARGER MAINTENANCE

Maintenance guidelines for the charger, including cleaning and cord care.

CHARGER TROUBLESHOOTING

Troubleshooting guide for charger issues.

Section 16 - Electric Vehicle - Motor

EXTERNAL MOTOR TESTING

Tests that can be performed without disassembling the motor.

MOTOR DISASSEMBLY

Steps for disassembling the motor for inspection or repair.

MOTOR COMPONENT TESTING AND INSPECTION

Procedures for testing and inspecting motor components like armature and brushes.

MOTOR ASSEMBLY

Steps for assembling the motor after component replacement or inspection.

MOTOR INSTALLATION

Procedures for installing the motor onto the transaxle.

Section 17 - Electric Vehicle - Transaxle

Lubrication

Information on transaxle lubrication and level indicators.

AXLE BEARING AND SHAFT

Procedures for removing and installing axle shafts, bearings, and oil seals.

Transaxle Removal

Detailed steps for removing the transaxle from the vehicle.

Transaxle Disassembly and Inspection

Steps for disassembling and inspecting the transaxle components.

Transaxle Assembly

Steps for reassembling the transaxle after disassembly.

Transaxle Installation

Steps for installing the transaxle back into the vehicle.

Section 18 - Gasoline Vehicle - Troubleshooting and Electrical System

LOW OIL WARNING LIGHT

Functionality of the low oil warning light and reset procedure.

FEATURES OF THE ELECTRONIC FUEL INJECTION (EFI) SYSTEM

Key features and specifications of the EFI system.

TROUBLESHOOTING GUIDE

Guides for identifying operating difficulties and their causes.

TEST PROCEDURES

Procedures for testing the gasoline vehicle's electrical system.

Section 19 - Gasoline Vehicle - Electrical Components

STARTER/GENERATOR

Information on testing, removing, and disassembling the starter/generator.

KEY SWITCH

Procedures for installing the key switch into the instrument panel.

MAINTENANCE/OPERATE SWITCH

Procedures for testing, removing, and installing the Maintenance/Operate switch.

NEUTRAL LOCKOUT LIMIT SWITCH

Procedures for testing, removing, and installing the neutral lockout limit switch.

SOLENOID

Procedures for testing, removing, and installing the solenoid.

BATTERY

Information on battery testing, preventive maintenance, and storage.

Section 20 - Gasoline Vehicle - Engine

General Information

Overview of the Subaru EX40 engine and its features.

VALVE CLEARANCE CHECK AND ADJUSTMENT

Procedures for checking and adjusting valve clearance on the engine.

ENGINE REMOVAL

Steps for removing the engine from the vehicle.

ENGINE INSTALLATION

Steps for installing the engine into the vehicle.

IGNITION COIL

Procedures for testing, removing, and installing the ignition coil.

Section 21 - Gasoline Vehicle - Fuel System

EFI SYSTEM FEATURES/SPECIFICATIONS

Key features and specifications of the EFI system.

REFUEL

Safety precautions and procedures for refueling the vehicle.

Relieving Fuel Pressure

Procedures to relieve fuel pressure before servicing the EFI system.

THROTTLE BODY

Information on inspecting and removing/installing the throttle body.

FUEL PUMP MODULE

Information on the fuel pump module, its components, and replacement.

FUEL TANK

Procedures for removing, disposing, storing, and installing the fuel tank.

FUEL FILTER

Information on fuel filter removal and installation.

Section 22 - Gasoline Vehicle - Exhaust System

MUFFLER

Procedures for removing and installing the muffler.

Section 23 - Gasoline Vehicle - Clutches

Drive Belt

Inspection, removal, and installation of the drive belt.

Drive Clutch

Procedures for removing, cleaning, inspecting, disassembling, and assembling the drive clutch.

Driven Clutch

Procedures for removing, disassembling, inspecting, and assembling the driven clutch.

Section 24 - Gasoline Vehicle - Transaxle

LUBRICATION

Procedures for checking lubricant levels and changing oil.

AXLE BEARING AND SHAFT

Procedures for removing and installing axle shafts, bearings, and oil seals.

TRANSAXLE REMOVAL

Detailed steps for removing the transaxle from the vehicle.

TRANSAXLE INSTALLATION

Steps for installing the transaxle back into the vehicle.

SHIFTER CABLE ADJUSTMENT

How to adjust the shifter cable for proper operation.

Section 25 - Wiring Diagrams

GENERAL INFORMATION

Information on wire description conventions and wire colors used in diagrams.

ELECTRIC: ACCESSORY WIRING DIAGRAM

Wiring diagram for electric vehicle accessories, including lights and turn signals.

ELECTRIC: MAIN HARNESS

Wiring diagram for the main harness of the electric vehicle.