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Villager 2
Maintenance and service manual
Club Car Villager 2 Maintenance And Service Manual
Electric vehicle with eric charging system gasoline vehicle with kohler ech440 engine
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Table of Contents
SECTION 1 - Safety
Safety Details
General Warnings
Disabling the Vehicle
Disconnect the Battery - Gasoline Vehicles
Connect the Battery - Gasoline Vehicles
Disconnect the Batteries - Electric Vehicles
Connect the Batteries - Electric Vehicles
Recycling Lead-Acid Batteries
International Safety Symbols on Batteries
SECTION 2 - Vehicle Specifications
Electric - Vehicle Specifications
Dimensions
Performance
Tires
Electric Motor
Batteries
Noise and Vibration
Transaxle
Vehicle Weights and Load Capacities
Gasoline - Vehicle Specifications
Dimensions
Performance
Tires
Gasoline Engine
Battery
Noise and Vibration
Transaxle
Vehicle Weights and Load Capacities
SECTION 3 - Extended Storage
Electric Vehicle Extended Storage
Extended Storage Preparation - Electric
Return to Service from Extended Storage - Electric
Gasoline Vehicle Extended Storage
Extended Storage Preparation - Gasoline
Return to Service from Extended Storage - Gasoline
SECTION 4 - Body and Trim
Cleaning the Windshield
Cleaning the Vehicle Exterior
Cleaning the Vehicle Interior
Body Repair
Stress Lines or Streaks
Minor Impact Damage/Deformations
Minor Scratches and Surface Blemishes
Gouges, Punctures, Tears, Large Scratches, and Abrasions
Seat Hinge
Seat Hinge Removal
Seat Hinge Installation
Hip Restraint
Hip Restraint Removal
Hip Restraint Installation
Front Body
Front Body Removal
Front Body Installation
Front Bumper
Headlight Adjustment
Aiming the Headlight Beam
Instrument Panel
Instrument Panel Removal
Instrument Panel Installation
Dash Assembly
Dash Assembly Removal
Dash Assembly Installation
Floor Mat and Retainers
Floor Mat Removal
Floor Mat Installation
Floor Mat Retainer Removal
Floor Mat Retainer Installation
Kick Plate and Charger Receptacle Bezel - Electric Vehicles
Kick Plate and Charger Receptacle Bezel Removal
Kick Plate and Charger Receptacle Bezel Installation
Kick Plate - Gasoline Vehicles
Kick Plate Removal
Kick Plate Installation
Access Panel
Access Panel Removal
Access Panel Installation
Visage Display Unit Overhead Baskets
Overhead Basket Removal
Overhead Basket Installation
Overhead Speaker Basket Removal
Overhead Speaker Basket Installation
Two-Passenger - Canopy
Two-Passenger Canopy Removal
Two-Passenger Canopy Installation
Two-Passenger Canopy with Visage Display Unit Removal
Two-Passenger Canopy with Visage Display Unit Installation
Two-Passenger Front Canopy Strut Removal
Two-Passenger Front Canopy Strut Installation
Two-Passenger Rear Canopy Support Removal
Two-Passenger Rear Canopy Support Installation
Two-Passenger - Rear Body
Universal Accessory Mounting
Structural Accessory Module (SAM)
Seat Back
Bag Rack Assembly
Bag Strap
Sweater Basket
Rear Beauty Panel
Rear Underbody
Rear Crossmember
Villager 4 - Monsoon Canopy
Monsoon Canopy Removal
Monsoon Canopy Installation
2+2 Front Canopy Strut Removal
2+2 Front Canopy Strut Installation
2+2 Rear Canopy Support Removal
2+2 Rear Canopy Support Installation
Villager 4 - Rear Body
Seat Backs
Fixed Rear Seat
Fold-Down Rear Seat
Seat Support
Foot Deck - 2+2
Rear Beauty Panel (2+2 Vehicles)
Rear Underbody
SECTION 5 - Accelerator and Brake Pedal Group
Pedal Group - Electric Vehicle
Pedal Group Removal
Mcor
Pedal Group Installation
Pedal Group - Gasoline Vehicle
Pedal Group Removal
Throttle Position Sensor
Pedal Group Installation
Debris Shields
Accelerator Pedal Removal
Accelerator Pedal Installation
Brake Pedal Removal
Brake Pedal Installation
SECTION 6 - Wheel Brake Assemblies
General Information
Brake Shoe Removal
Brake Assembly Cleaning
Brake Shoe Installation
Brake Cable Equalizer Adjustment
Brake Cluster
Brake Cluster Removal
Brake Cluster Installation
Brake Cable
Brake Cable Removal
Brake Cable Installation
SECTION 7 - Steering and Front Suspension
General Information
Steering Wheel
Steering Wheel Removal
Steering Wheel Installation
Steering Column
Steering Column Removal
Steering Column Installation
Rack and Pinion
Rack and Pinion Inspection
Rack and Pinion Removal
Rack and Pinion Installation
Front Suspension
Lubrication
Wheel Alignment
Front Suspension Components
Tie Rod End Removal
Tie Rod Installation
Leaf Spring Removal
Leaf Spring Installation
Kingpin and Steering Spindle Removal
Kingpin and Steering Spindle Installation
Control Arm Removal
Control Arm Installation
Front Shock Absorber Inspection
Front Shock Absorber Removal
Front Shock Absorber Installation
Front Wheel Hubs
Front Wheel Free Play Inspection
Front Wheel Hub Removal
Front Wheel Hub Installation
SECTION 8 - Wheels and Tires
General Information
Wheels
Wheel Removal
Wheel Installation
Tires
Tire Removal
Tire Repair
Tire Installation
SECTION 9 - Rear Suspension
General Information
Shock Absorbers
Rear Shock Absorber Inspection
Rear Shock Absorber Removal
Rear Shock Absorber Installation
Panhard and Bracket
Panhard and Bracket Removal
Panhard and Bracket Installation
Leaf Springs (Two-Passenger)
Leaf Spring Removal (Two-Passenger)
Leaf Spring Installation (Two-Passenger)
Leaf Springs (Four-Passenger)
Leaf Spring Removal (Four-Passenger)
Leaf Spring Installation (Four-Passenger)
Leaf Springs (Four-Passenger - Heavy Duty with Panhard)
Leaf Spring Removal (Four-Passenger - Heavy Duty with Panhard)
Leaf Spring Installation (Four-Passenger - Heavy Duty with Panhard)
SECTION 10 - Periodic Maintenance
General Information
Pre-Operation and Daily Safety Checklist
Performance Inspection
Maintenance
Periodic Service Schedules
Periodic Lubrication Schedules
Air Filter
Air Filter Removal
Air Filter Installation
Engine Oil
Engine Oil Viscosity
Engine Oil Level Inspection
Engine Oil Replacement
Add Engine Oil
SECTION 11 - Controller Diagnostic Tool (CDT)
General Information
Features
Plugging the CDT into the Vehicle
Introductory Display
Quick Reference Guide - Excel with ERIC Charging System
System Info
Model Number
Serial Number
Hardware Version
Protocol Version
Param Block Version
MFG Date Code
OS Version
SM Version
VCL App Version
Parameters
Settings
Amp Hours
Access Codes
Vehicle ID
Monitor Menu
Batt Voltage
Min I
Signed Battery Current
BDI Percent
Speed
Throttle
Temperature
Arm Current
Field Current
Armature PWM
Field PWM
Speed Pulses
Foot Input
Key Input
Forward Input
Reverse Input
Mode Switch Input
Charger Inhibit
Main Cont Driver
Password Tries (OEM Access Level Only)
Odometer
BDI Info
Battery Monitor
Charging Totals
Amp Hours Display
Lin
Vehicle Speeds
Pedal Counters
Fault Counters
Fault Count Odometers
Diagnostics Menu
Present Errors Folder
Fault History Folder
Causes of Faults
Fault Recovery
Fault Descriptions
Incorrect Password (OEM Access Level Only)
Max Password Tries (OEM Access Level Only)
Throttle Fault
Low Battery Voltage (Undervoltage)
Overvoltage
Thermal Cutback
Anti-Tamper Fault
Hpd
Main Drvr Overcurrent
Lockout Fault
Low SOC
Main Welded
High Speed Walkaway
Speed Sensor
Main Driver on
Main Coil Open
Main Dropout (1 or 2)
Motor Stall
Main Driver off
Current Sense Fault
M- Shorted
FLD (Field) Missing
HW Failsafe
Fault History
Clear Fault History
Programming
Cloning
Favorites
HHP Settings
Plot & Log
Plot
Log
CDT Troubleshooting
Connection Tests
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Download this manual
2020 Precedent,
Villager 2 and 4
Maintenance and
Service Manual
Electric Vehicle with ERIC Charging System
Gasoline Vehicle with Kohler ECH440 Engine
Manual Number 86753090004
Edition Code B
Table of
Contents
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Table of Contents
Troubleshooting
CDT Troubleshooting
208
SECTION 12 - Electric Vehicle - Troubleshooting and Electrical System
213
Troubleshooting
218
Troubleshooting Guide 2
221
Charger Troubleshooting
288
External Charger Troubleshooting Indicators
290
SECTION 18 - Gasoline Vehicle - Troubleshooting and Electrical System
335
Low Oil Warning Light
336
SECTION 23 - Gasoline Vehicle - Clutches
441
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