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Precedent Villager 2 2019
Club Car Precedent Villager 2 2019 Manuals
Manuals and User Guides for Club Car Precedent Villager 2 2019. We have
1
Club Car Precedent Villager 2 2019 manual available for free PDF download: Maintenance And Service Manual
Club Car Precedent Villager 2 2019 Maintenance And Service Manual (590 pages)
Electric Vehicle with ERIC Charging System Gasoline Vehicle with Kohler ECH440 Engine
Brand:
Club Car
| Category:
Golf Cars
| Size: 29.72 MB
Table of Contents
Table of Contents
7
SECTION 1 - Safety
19
Safety Details
19
General Warnings
20
Disabling the Vehicle
21
Disconnect the Battery - Gasoline Vehicles
21
Connect the Battery - Gasoline Vehicles
22
Disconnect the Batteries - Electric Vehicles
22
Connect the Batteries - Electric Vehicles
23
Recycling Lead-Acid Batteries
24
International Safety Symbols on Batteries
24
SECTION 2 - Vehicle Specifications
25
Electric - Vehicle Specifications
25
Dimensions
25
Performance
25
Tires
25
Electric Motor
25
Batteries
26
Noise and Vibration
26
Transaxle
26
Vehicle Weights and Load Capacities
26
Gasoline - Vehicle Specifications
27
Dimensions
27
Performance
28
Tires
28
Gasoline Engine
28
Battery
28
Noise and Vibration
28
Transaxle
28
Vehicle Weights and Load Capacities
29
SECTION 3 - Extended Storage
31
Electric Vehicle Extended Storage
31
Extended Storage Preparation - Electric
31
Return to Service from Extended Storage - Electric
32
Gasoline Vehicle Extended Storage
34
Extended Storage Preparation - Gasoline
34
Return to Service from Extended Storage - Gasoline
35
SECTION 4 - Body and Trim
37
Cleaning the Windshield
37
Cleaning the Vehicle Exterior
37
Cleaning the Vehicle Interior
38
Body Repair
38
Stress Lines or Streaks
38
Minor Impact Damage/Deformations
38
Minor Scratches and Surface Blemishes
39
Gouges, Punctures, Tears, Large Scratches, and Abrasions
39
Seat Hinge
40
Seat Hinge Removal
40
Seat Hinge Installation
40
Hip Restraint
41
Hip Restraint Removal
41
Hip Restraint Installation
41
Front Body
41
Front Body Removal
41
Front Body Installation
42
Front Bumper
44
Headlight Adjustment
45
Aiming the Headlight Beam
45
Instrument Panel
46
Instrument Panel Removal
46
Instrument Panel Installation
46
Dash Assembly
47
Dash Assembly Removal
47
Dash Assembly Installation
47
Floor Mat and Retainers
48
Floor Mat Removal
48
Floor Mat Installation
48
Floor Mat Retainer Removal
48
Floor Mat Retainer Installation
48
Kick Plate and Charger Receptacle Bezel - Electric Vehicles
50
Kick Plate and Charger Receptacle Bezel Removal
50
Kick Plate and Charger Receptacle Bezel Installation
51
Kick Plate - Gasoline Vehicles
52
Kick Plate Removal
52
Kick Plate Installation
52
Access Panel
53
Access Panel Removal
53
Access Panel Installation
53
Visage Display Unit Overhead Baskets
54
Overhead Basket Removal
54
Overhead Basket Installation
54
Overhead Speaker Basket Removal
55
Overhead Speaker Basket Installation
55
Two-Passenger - Canopy
56
Two-Passenger Canopy Removal
56
Two-Passenger Canopy Installation
57
Two-Passenger Canopy with Visage Display Unit Removal
57
Two-Passenger Canopy with Visage Display Unit Installation
59
Two-Passenger Front Canopy Strut Removal
61
Two-Passenger Front Canopy Strut Installation
62
Two-Passenger Rear Canopy Support Removal
63
Two-Passenger Rear Canopy Support Installation
64
Two-Passenger - Rear Body
64
Universal Accessory Mounting
64
Structural Accessory Module (SAM)
65
Seat Back
66
Bag Rack Assembly
67
Bag Strap
68
Sweater Basket
69
Rear Beauty Panel
70
Rear Underbody
71
Rear Crossmember
72
Villager 4 - Monsoon Canopy
73
Monsoon Canopy Removal
73
Monsoon Canopy Installation
74
2+2 Front Canopy Strut Removal
75
2+2 Front Canopy Strut Installation
76
2+2 Rear Canopy Support Removal
77
2+2 Rear Canopy Support Installation
78
Villager 4 - Rear Body
79
Seat Backs
79
Fixed Rear Seat
81
Fold-Down Rear Seat
84
Seat Support
88
Foot Deck - 2+2
89
Rear Beauty Panel (2+2 Vehicles)
93
Rear Underbody
94
SECTION 5 - Accelerator and Brake Pedal Group
95
Pedal Group - Electric Vehicle
95
Pedal Group Removal
95
Mcor
97
Pedal Group Installation
97
Pedal Group - Gasoline Vehicle
98
Pedal Group Removal
98
Throttle Position Sensor
99
Pedal Group Installation
100
Debris Shields
100
Accelerator Pedal Removal
100
Accelerator Pedal Installation
100
Brake Pedal Removal
101
Brake Pedal Installation
101
SECTION 6 - Wheel Brake Assemblies
103
General Information
103
Brake Shoe Removal
105
Brake Assembly Cleaning
107
Brake Shoe Installation
110
Brake Cable Equalizer Adjustment
114
Brake Cluster
115
Brake Cluster Removal
115
Brake Cluster Installation
117
Brake Cable
119
Brake Cable Removal
119
Brake Cable Installation
122
SECTION 7 - Steering and Front Suspension
125
General Information
125
Steering Wheel
125
Steering Wheel Removal
125
Steering Wheel Installation
126
Steering Column
128
Steering Column Removal
128
Steering Column Installation
129
Rack and Pinion
130
Rack and Pinion Inspection
130
Rack and Pinion Removal
130
Rack and Pinion Installation
131
Front Suspension
133
Lubrication
133
Wheel Alignment
133
Front Suspension Components
136
Tie Rod End Removal
136
Tie Rod Installation
136
Leaf Spring Removal
137
Leaf Spring Installation
138
Kingpin and Steering Spindle Removal
139
Kingpin and Steering Spindle Installation
140
Control Arm Removal
141
Control Arm Installation
142
Front Shock Absorber Inspection
143
Front Shock Absorber Removal
144
Front Shock Absorber Installation
144
Front Wheel Hubs
146
Front Wheel Free Play Inspection
146
Front Wheel Hub Removal
146
Front Wheel Hub Installation
147
SECTION 8 - Wheels and Tires
149
General Information
149
Wheels
149
Wheel Removal
149
Wheel Installation
149
Tires
150
Tire Removal
150
Tire Repair
150
Tire Installation
151
SECTION 9 - Rear Suspension
153
General Information
153
Shock Absorbers
153
Rear Shock Absorber Inspection
153
Rear Shock Absorber Removal
154
Rear Shock Absorber Installation
155
Panhard and Bracket
156
Panhard and Bracket Removal
156
Panhard and Bracket Installation
156
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 Maintenance
167
General Information
167
Pre-Operation and Daily Safety Checklist
167
Performance Inspection
168
Maintenance
169
Periodic Service Schedules
170
Periodic Lubrication Schedules
174
Air Filter
176
Air Filter Removal
176
Air Filter Installation
176
Engine Oil
176
Engine Oil Viscosity
176
Engine Oil Level Inspection
177
Engine Oil Replacement
178
Add Engine Oil
180
SECTION 11 - Controller Diagnostic Tool (CDT)
183
General Information
184
Features
184
Plugging the CDT into the Vehicle
185
Introductory Display
185
Quick Reference Guide - Excel with ERIC Charging System
186
System Info
187
Model Number
187
Serial Number
187
Hardware Version
187
Protocol Version
187
Param Block Version
187
MFG Date Code
187
OS Version
187
SM Version
187
VCL App Version
187
Parameters
188
Settings
188
Amp Hours
190
Access Codes
190
Vehicle ID
191
Monitor Menu
191
Batt Voltage
192
Min I
192
Signed Battery Current
192
BDI Percent
192
Speed
192
Throttle
192
Temperature
192
Arm Current
192
Field Current
192
Armature PWM
193
Field PWM
193
Speed Pulses
193
Foot Input
193
Key Input
193
Forward Input
193
Reverse Input
193
Mode Switch Input
193
Charger Inhibit
193
Main Cont Driver
193
Password Tries (OEM Access Level Only)
194
Odometer
194
BDI Info
194
Battery Monitor
194
Charging Totals
194
Amp Hours Display
195
Lin
195
Vehicle Speeds
195
Pedal Counters
195
Fault Counters
195
Fault Count Odometers
195
Diagnostics Menu
196
Present Errors Folder
196
Fault History Folder
196
Causes of Faults
197
Fault Recovery
199
Fault Descriptions
200
Incorrect Password (OEM Access Level Only)
200
Max Password Tries (OEM Access Level Only)
200
Throttle Fault
200
Low Battery Voltage (Undervoltage)
200
Overvoltage
200
Thermal Cutback
201
Anti-Tamper Fault
201
Hpd
201
Main Drvr Overcurrent
201
Lockout Fault
201
Low SOC
201
Main Welded
202
High Speed Walkaway
202
Speed Sensor
202
Main Driver on
202
Main Coil Open
202
Main Dropout (1 or 2)
203
Motor Stall
203
Main Driver off
203
Current Sense Fault
203
M- Shorted
203
FLD (Field) Missing
204
HW Failsafe
204
Fault History
204
Clear Fault History
204
Programming
204
Cloning
205
Favorites
205
HHP Settings
205
Plot & Log
207
Plot
207
Log
207
CDT Troubleshooting
208
Connection Tests
209
SECTION 12 - Electric Vehicle - Troubleshooting and Electrical System
213
General Information
213
Accessories
213
Charge Indicator Light
213
Attributes of the Excel System
213
Key Differences: Excel with ERIC Charging System Vs. Powerdrive Chargers
214
Features
214
Battery Wiring Diagram
216
Sonic Weld, Fuse, and 10K Ohm Resistor Locations
217
Troubleshooting
218
Troubleshooting the Vehicle with the CDT
218
Troubleshooting Guide 2
221
Test Procedures
224
Testing Basics
224
SECTION 13 - Electric Vehicle - Electrical Components
245
Key Switch
245
Testing the Key Switch
245
Key Switch Removal
245
Key Switch Installation
245
Charge Indicator Light
246
Testing the Charge Indicator Light
246
Charge Indicator Light Removal
246
Charge Indicator Light Installation
246
USB Port
247
USB Port Removal
247
USB Port Installation
248
Forward/Reverse Rocker Switch
248
Testing the Forward/Reverse Rocker Switch
248
Forward/Reverse Rocker Switch Removal
248
Forward/Reverse Rocker Switch Installation
249
Electronics Module Cover
250
Electronics Module Cover Removal
250
Electronics Module Cover Installation
250
Tow/Run Switch
251
Testing the Tow/Run Switch
251
Tow/Run Switch Removal
251
Tow/Run Switch Installation
251
Motor Controller Output Regulator (MCOR)
252
Testing the MCOR
252
MCOR Removal
252
MCOR Installation
252
Reverse Buzzer
253
Testing the Reverse Buzzer
253
Reverse Buzzer Removal
253
Reverse Buzzer Installation
253
Electronics Module
254
Electronics Module Removal
254
Electronics Module Installation
255
Speed Controller
256
Testing the Solid State Speed Controller
256
Speed Controller Removal
256
Speed Controller Installation
256
Solenoid
257
Testing the Solenoid
257
Solenoid Removal
257
Solenoid Installation
258
Charger Receptacle
258
Testing the Charger Receptacle
258
Charger Receptacle Inspection
258
Charger Receptacle Removal
258
Charger Receptacle Installation
259
SECTION 14 - Electric Vehicle - Batteries
261
General Information
261
Battery Testing Basics - 8 Volt
262
Observation
262
Measuring Voltage of Battery Set
262
Battery Cell Numbering
262
Battery Testing - 8 Volt
263
Battery Regrouping
263
Battery Replacement
265
Battery Care
266
Water Quality
266
Deionizer
267
Battery Care - Vehicles Equipped with the Single-Point Watering System
268
Battery Care - Vehicles Without the Single-Point Watering System
269
Self-Discharge
269
Electrolyte Level
270
Vibration Damage
270
Single Point Watering System (SPWS)
271
Initial Maintenance of the SPWS
271
Watering Batteries with the SPWS
271
Battery Storage
273
Fleet Rotation
273
Deep-Discharge
273
Early Excessive Discharging
273
SECTION 15 - Electric Vehicle - Battery Charger
275
General Information
276
USB Service Port
277
UL and CSA Listing
277
CE Compliance
277
Plug and Receptacle
277
Charger Power Connection Fuse
278
Charger Interlock
278
AC Input Voltage Detection
278
Thermal Cutback
278
Charge Indicator Light
278
External Charger Status Indicators
278
Onboard Charger Status Indicators
279
Long-Term Storage
280
External Charger Mounting
281
AC Power Connection
282
The Charge Circuit
283
Charger Operation
284
Charging Batteries
284
Charger Maintenance
287
USB Service Port Cleaning and Care
287
Charger Troubleshooting
288
Numbering Vehicles and Chargers
288
USB Service Port
288
Incoming AC Service
288
Terminal Block Cover
289
Resetting Power - External Charger
289
Resetting Power - Onboard Charger
289
External Charger Troubleshooting Indicators
290
Onboard Charger Fault Codes
292
Test Procedures
294
External Charger Repairs
297
Terminal Block Cover Removal
297
Terminal Block Cover Installation
298
DC Cord and Strain Relief Removal
298
DC Cord and Strain Relief Installation
298
Handle Removal
298
Handle Installation
299
Foot Removal
299
Foot Installation
299
Onboard Charger Repairs
300
Onboard Charger Removal
300
Onboard Charger Installation
301
Terminal Block Cover Removal
301
Terminal Block Cover Installation
301
DC Cord and Strain Relief Removal
302
DC Cord and Strain Relief Installation
302
DC Charging Harness Removal
302
DC Charging Harness Installation
303
SECTION 16 - Electric Vehicle - Motor
305
General Information
305
External Motor Testing
305
Motor
308
Motor Removal
308
Motor Disassembly
309
Motor Component Testing and Inspection
312
Armature Inspection and Testing
312
Motor Frame and Field Windings Inspection
314
Motor Brush, Spring, and Terminal Insulator Inspection
314
Reconditioning the Motor
317
Motor Specifications
317
Motor Assembly
317
Motor Installation
319
SECTION 17 - Electric Vehicle - Transaxle
323
Lubrication
323
Axle Bearing and Shaft
323
Axle Shaft
323
Axle Bearing
326
Transaxle Removal
327
Transaxle Disassembly, Inspection, and Assembly
329
Transaxle Disassembly and Inspection
329
Transaxle Assembly
331
Transaxle Installation
332
SECTION 18 - Gasoline Vehicle - Troubleshooting and Electrical System
335
General Information
335
Accessories
335
Features of the Electronic Fuel Injection (EFI) System
335
Ground Locations
335
Low Oil Warning Light
336
Malfunction Indicator Light
336
Troubleshooting Guide
336
Gasoline Powertrain
337
Fuse and Relay Locations
339
Electrical System
340
Test Procedures
341
Testing Basics
341
SECTION 19 - Gasoline Vehicle - Electrical Components
367
Battery
367
General Information
367
Preventive Maintenance
368
Self-Discharge
368
Vibration Damage
368
Battery Removal
369
Charging the Battery
369
Battery Installation
369
Battery Storage
370
Charging a Dead Battery
370
Ground Cables
370
Starter/Generator
370
Starter/Generator Removal
370
Disassembly of the Starter/Generator to Service the Brushes
371
Brush Inspection and Replacement
371
Brush Spring Inspection and Replacement
372
Starter/Generator Assembly
372
Disassembly of the Starter/Generator to Service the Armature/Commutator
373
Bearing Cleaning and Inspection
374
Bearing Removal
375
Field Coil Assembly
375
Visual Inspection of Armature
375
Commutator Cleaning and Inspection
376
Armature Ground Test
377
Visual Inspection of Field Coils
378
Starter/Generator Rework
378
Starter/Generator Assembly
378
Starter/Generator Installation
381
Belt Tension Adjustment for EFI Engines
382
Solenoid
384
Solenoid Removal
384
Solenoid Installation
385
Voltage Regulator
386
Voltage Regulator Removal
386
Voltage Regulator Installation
387
Engine Control Unit (ECU)
387
Engine Control Unit Removal
387
Engine Control Unit Installation
388
Fuel Level Sending Unit
388
Maintenance/Operate Switch
388
Maintenance/Operate Switch Removal
388
Maintenance/Operate Switch Installation
389
Accelerator Pedal Limit Switch
389
Kill Limit Switch
390
Multi-Purpose Buzzer Limit Switch
390
Multi-Purpose Buzzer Limit Switch Removal
390
Multi-Purpose Buzzer Limit Switch Installation
391
Neutral Lockout Limit Switch
391
Neutral Lockout Limit Switch Removal
391
Neutral Lockout Limit Switch Installation
392
Transaxle Limit Switch
393
Transaxle Limit Switch Removal
393
Transaxle Limit Switch Installation
393
Brake Light Relay
394
Brake Light Relay Removal
394
Brake Light Relay Installation
395
Fuel Gauge/Hour Meter
395
General Information
395
Fuel Gauge/Hour Meter Removal
396
Fuel Gauge/Hour Meter Installation
396
Headlight Switch
397
Headlight Switch Removal
397
Headlight Switch Installation
397
Key Switch
398
Key Switch Removal
398
Key Switch Installation
398
Low Oil Warning Light
399
Low Oil Warning Light Removal
399
Low Oil Warning Light Installation
399
Malfunction Indicator Light (MIL)
400
Malfunction Indicator Light Removal
400
Malfunction Indicator Light Installation
400
Multi-Purpose Buzzer
401
Multi-Purpose Buzzer Removal
401
Multi-Purpose Buzzer Installation
401
USB Receptacle
402
USB Receptacle Removal
402
USB Receptacle Installation
402
Oxygen Sensor
403
Oxygen Sensor Removal
403
Oxygen Sensor Installation
403
SECTION 20 - Gasoline Vehicle - Engine
405
General Information
405
Before Servicing
405
Engine Removal
406
Engine Installation
409
Snubber
412
Snubber Removal
412
Snubber Installation
412
SECTION 21 - Gasoline Vehicle - Fuel System
413
General Information
413
EFI System Features/Specifications
413
Engine Control Linkages
414
General Information
414
Ground Speed
414
Governor Cable
414
Accelerator Cable
417
Idle Adjustment
420
How to Measure Ground Speed
420
Engine RPM Adjustment
421
Air Intake System
422
Air Cleaner Removal
422
Air Cleaner Installation
422
Relieving Fuel Pressure
423
To Relieve Fuel Pressure
423
Carbon Canister
424
Carbon Canister Removal
424
Carbon Canister Installation
424
Fuel Line
425
Fuel Line Removal
425
Fuel Line Installation
427
Fuel Pump Module
429
General Information
429
Fuel Pump Module Removal
429
Fuel Pump Module Installation
431
Fuel Tank
432
General Information
432
Fuel Tank Removal
432
Fuel Tank Disposal
434
Fuel Tank Storage
434
Fuel Tank Installation
434
Fuel Filter
436
General Information
436
Fuel Filter Removal
436
Fuel Filter Installation
437
SECTION 22 - Gasoline Vehicle - Exhaust System
439
Muffler
439
Muffler Removal
439
Muffler Installation
440
SECTION 23 - Gasoline Vehicle - Clutches
441
General Information
441
Troubleshooting
441
Drive Belt
443
Drive Belt Removal
443
Drive Belt Installation
443
Drive Clutch
444
Drive Clutch Removal
445
Drive Clutch Cleaning and Inspection
446
Drive Clutch Disassembly
446
Inspection of Drive Clutch Parts
449
Drive Clutch Assembly
450
Drive Clutch Installation
451
Driven Clutch
452
Driven Clutch Removal
453
Driven Clutch Disassembly
453
Driven Clutch Inspection
455
Driven Clutch Assembly
456
Driven Clutch Installation
458
SECTION 24 - Gasoline Vehicle - Transaxle
459
General Information
459
Shifter Lever
459
Maintenance/Operate Switch
459
Governor System
460
Transaxle Service
460
Lubrication
460
Tools Required for this Section
461
Rear Hubs
462
Rear Hub Removal
462
Rear Hub Installation
462
Axle Tubes, Axle Shafts and Wheel Bearings
464
Axle Tube and Axle Shaft Removal
464
Axle Tube and Axle Shaft Installation
465
Rear Wheel Bearing Removal
465
Rear Wheel Bearing Installation
465
Axle Shaft Oil Seal Removal
465
Axle Shaft Oil Seal Installation
466
Transaxle Removal
467
Transaxle Installation
470
Forward/Neutral/Reverse Handle
471
Forward/Neutral/Reverse Handle Removal
471
Forward/Neutral/Reverse Handle Installation
471
Shifter Cable
471
Shifter Cable Removal
471
Shifter Cable Installation
472
Shifter Cable Adjustment
472
SECTION 25 - Kohler Engine Service Manual
475
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