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Club Car Precedent Villager 2, Maintenance And Service Manual

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15

External Charger Repairs

ELECTRIC VEHICLE - BATTERY CHARGER

2791

Figure 15-9

Terminal Block Cover Mounting Tabs

TERMINAL BLOCK COVER INSTALLATION

WARNING

• The terminal block cover (3) on the DC terminal block (4) must be installed properly to comply with UL

code. This cover prevents water exposure and prevents a short across the DC terminals.

1.

Align cover (3) with terminal block (4) and push onto block until tabs lock into place.

DC CORD AND STRAIN RELIEF REMOVAL

1.

Disconnect DC cord (1) from vehicle.

2.

Disconnect AC cord (2) from AC outlet.

3.

Remove two torx screws (5) securing strain relief (6) to charger.

4.

Remove terminal block cover (3).

See Terminal Block Cover Removal on page 15-19.

5.

Remove torx screw (7) securing each DC cord wire to terminal block (4).

DC CORD AND STRAIN RELIEF INSTALLATION

1.

Attach DC cord white wire to positive terminal (+) and black wire to negative terminal (–) with torx screws (7).

See

following NOTE.

Tighten screws (7) to 39.8 in·lb (4.5 N·m).

NOTE:

The positive symbol (+) and negative symbol (–) are molded into the terminal block for easy identification.

2.

Install terminal block cover (3).

See Terminal Block Cover Installation on page 15-20.

3.

Secure strain relief (6) to charger with torx screws (5). Tighten screws (5) to 27 in·lb (3.1 N·m).

HANDLE REMOVAL

Remove torx screws (8) securing handle (9) to charger.

Page 15-20

2019 Precedent Villager 2 Maintenance and Service Manual

Summary of Contents for Precedent Villager 2

Page 1: ...2019 Precedent Villager 2 Maintenance and Service Manual Electric Vehicle with ERIC Charging System Gasoline Vehicle with Subaru EX40 Engine Manual Number 105355116 Edition Code B...

Page 2: ......

Page 3: ...owners Regional technical representatives vehicle service seminars periodic service bulletins maintenance and service manuals and other service publications also represent Club Car s continuing commit...

Page 4: ...le read complete section s and any referenced information that may be relevant to the service or repair to be performed NOTE This manual represents the most current information at the time of publicat...

Page 5: ...3 6 SECTION 4 Body and Trim 4 1 Cleaning the Vehicle 4 1 Seat 4 1 Front and Rear Body Repair 4 2 Stress Lines or Streaks 4 2 Minor Impact Damage Deformations 4 2 Minor Scratches and Surface Blemishes...

Page 6: ...ke Cable Installation 6 13 SECTION 7 Steering and Front Suspension 7 1 General Information 7 1 Steering Wheel 7 1 Steering Wheel Removal 7 1 Steering Wheel Installation 7 2 Steering Column 7 2 Steerin...

Page 7: ...riodic Lubrication Schedules 10 8 SECTION 11 Controller Diagnostic Tool CDT 11 1 General Information 11 2 Features 11 2 Plugging the CDT into the Vehicle 11 3 Introductory Display 11 3 Quick Reference...

Page 8: ...ssword OEM Access Level Only 11 18 Max Password Tries OEM Access Level Only 11 18 Throttle Fault 11 18 Low Battery Voltage Undervoltage 11 18 Overvoltage 11 18 Thermal Cutback 11 19 Anti Tamper Fault...

Page 9: ...ctronics Module Cover 13 5 Electronics Module Cover Removal 13 5 Electronics Module Cover Installation 13 5 Tow Run Switch 13 6 Testing the Tow Run Switch 13 6 Tow Run Switch Removal 13 6 Tow Run Swit...

Page 10: ...e 15 4 Charger Interlock 15 4 AC Input Voltage Detection 15 4 Thermal Cutback 15 4 Charge Indicator Light 15 4 Charger Status Indicators 15 4 Long term Storage 15 5 External Charger Mounting 15 6 AC P...

Page 11: ...Low Oil Warning Light 18 2 Gasoline Powertrain 18 4 Sonic Weld Fuse and Diode Locations 18 8 Electrical System 18 9 Test Procedures 18 10 Testing Basics 18 10 SECTION 19 Gasoline Vehicle Electrical C...

Page 12: ...9 25 Reverse Buzzer Limit Switch Installation 19 25 Low Oil Warning Light 19 27 Low Oil Warning Light Removal 19 27 Low Oil Warning Light Installation 19 27 Fuel Gauge 19 28 Fuel Gauge Removal 19 28 F...

Page 13: ...Engine Control Linkages 21 8 General Information 21 8 Ground Speed 21 9 Governor Cable 21 9 Accelerator Cable 21 10 Closed Throttle or Idle Adjustment Pedal Start Vehicles 21 12 How to Measure Ground...

Page 14: ...Shifter Lever 24 1 Neutral Lockout 24 1 Governor System 24 2 Transaxle Service 24 2 Lubrication 24 2 Tools Required For This Section 24 3 Rear Hubs 24 4 Rear Hub Removal 24 4 Rear Hub Installation 24...

Page 15: ...ed If any of the operation or safety decals on the vehicle become damaged have been removed or cannot be easily read they should be replaced immediately to avoid possible property damage personal inju...

Page 16: ...ot ride in vehicle Do not leave children unattended on vehicle Prior to leaving the vehicle unattended or servicing the vehicle set the park brake place the Forward Reverse handle or switch in the NEU...

Page 17: ...disconnecting battery cables or other electrical wiring Do not allow a positive wire to touch the vehicle frame engine or any other metal component DISABLING THE VEHICLE 1 Set the park brake 2 Turn t...

Page 18: ...TING THE BATTERIES ELECTRIC VEHICLES 1 Disable the vehicle See Disabling the Vehicle on page 1 3 2 Place Tow Run switch in the TOW position before disconnecting or connecting the batteries Failure to...

Page 19: ...teries but by people who use the batteries as well Please contact your nearest Club Car dealer or distributor for information on how to properly recycle your batteries 1403 Figure 1 3 Dispose of Lead...

Page 20: ...Pagination Page 1 General Warnings SAFETY Page 1 6 2019 Precedent Villager 2 Maintenance and Service Manual...

Page 21: ...e Precision helical gears forward reverse with neutral position 11 47 1 forward 15 63 1 reverse with optional limited slip differential Torque converter Automatic variable speed dry type Electrical sy...

Page 22: ...30 6 km h Curb clearance circle diameter 17 ft 4 in 528 cm 17 ft 4 in 528 cm Standard seating capacity 2 2 LIQUID CAPACITIES Engine crankcase 40 fl oz 1 2 L Transaxle 22 fl oz 0 67 L 67 6 fl oz 2 L F...

Page 23: ...voltage VDC 48 Maximum DC voltage VDC 72 Maximum DC output current amps 13 5 DIMENSIONS WEIGHT Case overall length 9 9 in 25 2 cm Case overall width 7 3 in 18 6 cm Case overall height 3 1 in 8 cm AC c...

Page 24: ...Pagination Page 2 E R I C Battery Charger Specifications VEHICLE SPECIFICATIONS Page 2 4 2019 Precedent Villager 2 Maintenance and Service Manual...

Page 25: ...passenger side cup holder or above the accelerator or brake pedal Example CC5819 123456 Figure 3 1 The two letters 1 at the beginning of the serial number indicate the vehicle model The following four...

Page 26: ...ld be driven Ensuring that proper warnings of driving hazards are displayed and visible See below for list of signs available from Club Car Service Parts Department Who should and who should not drive...

Page 27: ...in each battery cell If water is required fill the cells to cover the plates charge the batteries and then use distilled water to fill each cell to the correct level Electrolyte level should be from...

Page 28: ...storage The charger will automatically activate when necessary 12 2 Check the electrolyte level and charger function monthly to ensure that proper operation is maintained The charger is functioning pr...

Page 29: ...10 amps or less 3 Seal the fuel tank 3 1 Fill fuel tank and following manufacturer s directions add a commercially available fuel stabilizer 3 2 Disconnect fuel vent line from fuel tank vent nipple 3...

Page 30: ...le in the NEUTRAL position and the neutral lockout switch in the MAINTENANCE position Crank the engine until fuel is pumped into the fuel injector and fuel lines and the engine starts Turn the engine...

Page 31: ...ing or rubbing compounds these will permanently dull the gloss Battery acid fertilizers tars asphalt creosote paint or chewing gum should be removed immediately to prevent possible stains See followin...

Page 32: ...he streak fades 3 It may be necessary to move the gun closer to the body to fade the streak but under no circumstance should the gun be held closer than 6 inches 15 cm to the body See following CAUTIO...

Page 33: ...gure 4 1 Page 4 4 2 Pull the front beauty panel 3 up and away from the brow and fascia assembly 4 disengaging the snap tabs 3 If the vehicle is equipped with a canopy loosen the canopy support cover t...

Page 34: ...4 Front Body BODY AND TRIM 3 8 2 1 5 6 7 4 616 Figure 4 1 Front Body Page 4 4 2019 Precedent Villager 2 Maintenance and Service Manual...

Page 35: ...4 5 Each bracket is secured in place by two taptite screws 2 tightened to 13 ft lb 17 6 N m The front bumper 3 is attached to the vehicle frame rails by nuts 5 and bolts 4 The nuts are tightened to 1...

Page 36: ...ng horizontal line 15 1 2 inches 39 4 cm above the ground directly in front of the vehicle 3 Turn on headlight Take note where the beam strikes the vertical surface in relation to the marked horizonta...

Page 37: ...forward edge engage to front underbody Secure assembly in place with two screws 5 and plastic rivet 6 Figure 4 4 Page 4 7 Tighten screws to 8 8 ft lb 12 N m 2 Install the instrument panel 2 1 Connect...

Page 38: ...m top of retainer 1 Figure 4 5 Page 4 8 2 Remove push rivets 4 from rear corners of retainer 3 Carefully pull on retainer to separate the trim clips from their respective slots Trim clips do not norma...

Page 39: ...the forward portion of the rear beauty panel to disengage it from the tabs on the upper portion of the kick plate 5 Remove kick plate from vehicle KICK PLATE AND CHARGER RECEPTACLE BEZEL INSTALLATION...

Page 40: ...to disengage it from the tabs on the upper portion of the kick plate 4 Remove kick plate from vehicle KICK PLATE INSTALLATION 1 Position the kick plate 2 on the vehicle and secure with three screws 1...

Page 41: ...eral Warnings on page 1 2 UNIVERSAL ACCESSORY MOUNTING NOTE The Structural Accessory Module SAM uses clearance holes for accessories to attach to the canopy support located inside the SAM The Structur...

Page 42: ...lb 5 8 N m Bag Rack Removal 1 Remove two screws 10 to release the bag hoop 6 and related components from the SAM 3 Figure 4 10 Page 4 13 2 Bag strap 8 may be released by removing two plastic barrel co...

Page 43: ...7 8 12 9 9 12 2 3 4 1 7 5 11 2653 Figure 4 10 Seat Back Bag Rack and SAM REAR BODY COMPONENTS Rear Beauty Panel Removal 1 Remove SAM See SAM Removal on page 4 12 2019 Precedent Villager 2 Maintenance...

Page 44: ...th two screws 14 Tighten screws to 20 in lb 2 3 N m 4 Position canopy support brackets 1 and 2 on vehicle and secure each with one screw 3 Tighten screws to 53 in lb 6 N m Access Panel Access panel 6...

Page 45: ...BODY AND TRIM Rear Body 4 11 11 10 10 15 13 5 4 5 7 6 12 2 3 1 14 Figure 4 11 Rear Body Components 2019 Precedent Villager 2 Maintenance and Service Manual Page 4 15...

Page 46: ...Pagination Page 4 Rear Body BODY AND TRIM Page 4 16 2019 Precedent Villager 2 Maintenance and Service Manual...

Page 47: ...loor mat 2 over the pedal group to gain access to the pedal group hardware 1 2 3 629 Figure 5 1 Pedal Group Access 4 Remove fastener 10 and lift off cover plate 7 Figure 5 2 Page 5 2 5 Loosen jam nuts...

Page 48: ...edal Group Electric Vehicle ACCELERATOR AND BRAKE PEDAL GROUP 7 10 2 1 3 6 4 5 11 9 8 13 12 2518 Figure 5 2 Pedal Group Electric Vehicle Page 5 2 2019 Precedent Villager 2 Maintenance and Service Manu...

Page 49: ...e and secure with two screws 2 on the driver side and two screws 1 on the passenger side Tighten driver side screws 2 to 97 in lb 11 N m Tighten passenger side screws 1 to 18 in lb 2 N m 3 Remove the...

Page 50: ...5 Loosen jam nuts 4 and 5 on each side of turnbuckle 6 NOTE Nut 4 has a left hand thread 6 Loosen turnbuckle 6 until the threaded rod 8 from the pedal group 11 is free of the turnbuckle Figure 5 4 Pa...

Page 51: ...erator pedal assembly The throttle position sensor detects the position of the accelerator pedal and sends a voltage to the solenoid and forward reverse limit switches The throttle position sensor its...

Page 52: ...stall the floor mat 2 over the pedal group Make sure tabs on floor mat sides are beneath the sill 3 Tighten screws 1 to 53 in lb 6 N m Figure 5 3 Page 5 4 8 Connect battery and spark plug wire s See C...

Page 53: ...nd 5 Figure 5 5 Page 5 8 3 Remove four screws 12 securing brake pedal assembly 8 to pedal group mounting plate and pull brake pedal assembly through bottom of pedal group mounting plate BRAKE PEDAL IN...

Page 54: ...5 Brake Pedal Installation ACCELERATOR AND BRAKE PEDAL GROUP Figure 5 5 Accelerator Pedal Assembly and Brake Pedal Assembly Page 5 8 2019 Precedent Villager 2 Maintenance and Service Manual...

Page 55: ...tery and spark plug wire s See Disconnecting the Battery Gasoline Vehicles on page 1 3 2 Place chocks at the front wheels Loosen but do not remove lug nuts on rear wheels and lift the rear of the vehi...

Page 56: ...brake drum to be pulled free After completing step 8 skip step 9 NOTE Although step 8 allows easier access to the brake shoes it is not imperative to do so in order to remove the brake shoes 8 For ele...

Page 57: ...18100 10222 Figure 6 3 Remove Shoe Retainer Clip 1400 17700 10225 Figure 6 4 Remove Brake Shoes 1 2 3 1 1 Slide 2732 Figure 6 5 Remove Adjuster Wheel 2733 Figure 6 6 Lubricate Slide 2019 Precedent Vi...

Page 58: ...rsonal injury 4 Use a small brush to carefully apply a light coat of white lithium NLGI 2 grease Dow Corning BR2 Plus or equivalent on each of the six raised bosses on the brake backing plate Figure 6...

Page 59: ...ASSEMBLIES Brake Assembly Cleaning 6 1 7 T 2735 Figure 6 9 Apply Grease To Brake Adjuster 2736 Figure 6 10 Install Adjuster Wheel Trailing Shoe 2019 Precedent Villager 2 Maintenance and Service Manua...

Page 60: ...ard the rear of the vehicle 2 Install the shoe retainer clip using pliers to compress the clip 1 while turning the retainer pin 2 into position Figure 6 11 Page 6 6 3 Attach the springs onto the trail...

Page 61: ...drum and make sure that it is properly seated See following NOTE NOTE If drum installation is difficult the brake shoes may need to be adjusted vertically in the mounting slots 9 After the drum is ins...

Page 62: ...ply Loctite 242 on the threads for both front and rear jam nuts 4 Tighten the rear jam nut first to 208 in lb 23 5 N m then tighten the front jam nut to 208 in lb 23 5 N m See following WARNING For op...

Page 63: ...6 1 Page 6 2 Note that the forward jam nut 1 is a left hand thread Thread each nut approximately 1 2 inch 12 7 mm away from the turnbuckle 5 Loosen turnbuckle 2 to release tension on the equalizer bra...

Page 64: ...ing axle shaft clean any residual oil from the exposed end of the axle tube and from the oil seal area 2 Be sure bolts 11 and new lock nuts 10 are used to mount the brake assembly Figure 6 17 Page 6 1...

Page 65: ...ion 6 5 Tighten lug nuts on rear wheels using a crisscross pattern to 55 ft lb 74 6 N m See Wheel Installation on page 8 1 6 Adjust the brakes See Brake Cable Equalizer Adjustment on page 6 8 2019 Pre...

Page 66: ...turnbuckle 5 Loosen turnbuckle 2 until the bolt 5 is free of the turnbuckle 1 4 3 2 5 6 7 650 Figure 6 18 Loosen Brake Cables 6 Rotate the bolt 5 and equalizer bracket 4 to the upright position then s...

Page 67: ...e hole 2 Hold the bolt 5 and the equalizer bracket 4 in the upright position and slip the cable head through the hole on top of the bracket Pivot the equalizer to the horizontal position to capture th...

Page 68: ...Pagination Page 6 Brake Cable Removal and Installation WHEEL BRAKE ASSEMBLIES Page 6 14 2019 Precedent Villager 2 Maintenance and Service Manual...

Page 69: ...steering wheel to a straight ahead position NOTE Do not turn steering again until wheel has been installed 3 Remove two screws 1 securing cover 2 to steering wheel 3 Figure 7 1 Page 7 2 4 Loosen and r...

Page 70: ...ic Vehicles Section 1 Page 1 4 Gasoline Vehicle Connect battery and spark plug wire s See Connecting the Battery Gasoline Vehicles on page 1 3 STEERING COLUMN See General Warnings on page 1 2 STEERING...

Page 71: ...3 3 Align the holes in the steering column mounting bracket with holes in the vehicle frame Secure column to frame with four bolts 10 Tighten bolts to 18 4 ft lb 25 N m 4 Tighten universal joint bolt...

Page 72: ...as a bent tie rod check the steering gear for abnormal free play noise binding or clunking while it is under a load With the steering system fully assembled and all four tires on the ground floor tur...

Page 73: ...ompound to the end of the steering column shaft 2 Simultaneously slide the universal joint over the square end of the steering column shaft and position the assembly over the mounting holes in the cha...

Page 74: ...e floor or ground there should be an equal amount of space between each tire and the framing square Figure 7 5 Page 7 7 2 Loosen but do not remove the four bolts 17 that secure the leaf spring 13 to t...

Page 75: ...rear facing surfaces of the tires and then roll the vehicle forward one and a half wheel revolutions until the marks appear on the forward facing surfaces of the tires at about the same height from t...

Page 76: ...ntroller See Disconnecting the Batteries Electric Vehicles on page 1 4 Gasoline Vehicle Disconnect battery and spark plug wire s See Disconnecting the Battery Gasoline Vehicles on page 1 3 2 Loosen ja...

Page 77: ...7 13 2 Install leaf spring 13 bottom spring plate 16 and four bolts 17 Using a crisscross pattern sequence tighten bolts to 37 ft lb 50 N m 3 Install spring in kingpins 7 with bolts 8 Tighten to 30 ft...

Page 78: ...cle Connect battery and spark plug wire s See Connecting the Battery Gasoline Vehicles on page 1 3 CONTROL ARM REMOVAL 1 Electric Vehicle Disconnect the batteries and discharge the controller See Disc...

Page 79: ...rs should be replaced 2 Remove the upper bolt 18 Figure 7 10 Page 7 12 3 Remove the lower bolt 10 4 Remove the shock absorber SHOCK ABSORBER INSTALLATION NOTE When installing shock absorbers make sure...

Page 80: ...ension Components STEERING AND FRONT SUSPENSION 4 8 11 10 2 5 6 7 9 6 4 1 2 14 13 12 16 17 19 18 1311 Figure 7 10 Upper Front Suspension Assembly Page 7 12 2019 Precedent Villager 2 Maintenance and Se...

Page 81: ...D FRONT SUSPENSION Front Suspension Components 7 1 3 4 5 4 6 7 8 9 10 11 13 14 15 16 17 18 19 3 1312 Figure 7 11 Lower Front Suspension Assembly 2019 Precedent Villager 2 Maintenance and Service Manua...

Page 82: ...7 11 Page 7 13 3 Slide the hub assembly 9 off of the spindle shaft 3 4 Lightly sand spindle shaft to clean away any light rust 5 Inspect the surface of the spindle shaft for surface damage It should...

Page 83: ...STEERING AND FRONT SUSPENSION Front Wheel Bearings and Hubs 7 3 11 9 678 Figure 7 12 Front Wheel Hub 2019 Precedent Villager 2 Maintenance and Service Manual Page 7 15...

Page 84: ...Pagination Page 7 Front Wheel Bearings and Hubs STEERING AND FRONT SUSPENSION Page 7 16 2019 Precedent Villager 2 Maintenance and Service Manual...

Page 85: ...ectric Vehicles on page 1 4 Gasoline Vehicle Disconnect battery and spark plug wire s See Disconnecting the Battery Gasoline Vehicles on page 1 3 2 Slightly loosen the lug nuts on the wheel to be remo...

Page 86: ...ot use excessive force when starting the bead over the edge of the rim 4 When top bead is free of the rim pull the bead from the bottom side of the rim up into the upper part of the rim well Insert th...

Page 87: ...4 Install the tire on the rim from the valve stem side If there is no tire machine available use a rubber mallet and tire iron 5 Remove the valve core and position tire so that both beads are on the r...

Page 88: ...8 Tires WHEELS AND TIRES 680 Figure 8 2 Inflate Tire Page 8 4 2019 Precedent Villager 2 Maintenance and Service Manual...

Page 89: ...damage or fluid leakage at the point where the shaft enters the shock absorber body Replace damaged or leaking shock absorbers Figure 9 3 Page 9 4 2 To remove a shock absorber remove the nut 5 cup was...

Page 90: ...t remain on the floor When not performing a test or service procedure that requires movement of the wheels lock the brakes 3 Place a floor jack under the transaxle differential casing to support but n...

Page 91: ...ting hole in the transaxle saddle 2 Tighten the nuts on the U bolts to 25 ft lb 34 N m and tighten nuts 2 on spring mounting bolts 17 to 18 5 ft lb 25 N m Figure 9 3 Page 9 4 3 Install tire and wheel...

Page 92: ...af Springs REAR SUSPENSION 5 7 4 3 17 17 2 4 2 11 12 13 15 10 9 9 19 14 18 3 4 16 1 2689 Figure 9 3 Rear Suspension Assembly and Mounting Page 9 4 2019 Precedent Villager 2 Maintenance and Service Man...

Page 93: ...trained technician Any vehicle not functioning correctly should be removed from use until it is properly repaired This will prevent further damage to the vehicle and avoid the possibility of injury d...

Page 94: ...mance Have a Club Car distributor dealer or a trained technician investigate anything unusual Electric Vehicles Accelerator With the key switch in the ON position and the Forward Reverse switch in the...

Page 95: ...se until it is properly repaired This will prevent further damage to the vehicle and avoid the possibility of injury due to unsafe conditions Contact your local Club Car distributor dealer to perform...

Page 96: ...E Initial one time inspection by owner or trained technician after six weeks of use Batteries For vehicles newly equipped with the Single Point Watering System For vehicles equipped with the SPWS manu...

Page 97: ...on 7 Steering and Front Suspension in the appropriate maintenance and service manual Safety decals Check safety decals Replace if damaged or illegible Batteries If batteries are not performing as expe...

Page 98: ...ru EX40 on page 2 1 Monthly service by owner or trained technician General vehicle Wash engine compartment and underside of vehicle Do not wash engine when hot Battery Clean terminals and wash dirt fr...

Page 99: ...hose for cracks Pedal group Lubricate all rotating joints See Periodic Lubrication Schedules on page 10 8 General vehicle Check for loose hardware tighten if necessary Refer to the appropriate mainten...

Page 100: ...ithium grease NLGI 2 Semiannually by owner or trained technician every 50 hours of operation Front suspension two fittings Chassis Lube EP NLGI Grade 2 Check fill transaxle to plug level 22 fl oz 0 67...

Page 101: ...nt suspension two fittings Chassis Lube EP NLGI Grade 2 Transaxle Check fill to plug level 67 6 fl oz 2 L SAE 80W 90 API Class GL 5 Annually by trained technician only every 100 hours of operation Ped...

Page 102: ...Pagination Page 10 Periodic Lubrication Schedules PERIODIC MAINTENANCE Page 10 10 2019 Precedent Villager 2 Maintenance and Service Manual...

Page 103: ...the CDT to troubleshoot the vehicle and to adjust controller parameters that affect vehicle behavior The Excel controller with OS version 34 or version 35 The OS version can be viewed in the System In...

Page 104: ...ault are also provided Help function Help screens give descriptions of adjustable parameters monitored variables and faults PC interface Files can be downloaded from a PC onto an Secure Digital SD car...

Page 105: ...Immediately after the CDT is connected to the vehicle it begins loading controller information During this time the loading status is shown as a percentage the CDT s software version is given and stat...

Page 106: ...error Lockout Fault This is a symptom not a cause Inspect and test the charger interlock circuit If no problems are found in the charger interlock circuit replace the controller Overvoltage Controller...

Page 107: ...See following NOTE NOTE This manual covers hardware version 5 PROTOCOL VERSION Displays the controller protocol version PARAM BLOCK VERSION Displays a number that represents the default parameter set...

Page 108: ...eed setting of 4 cannot be selected with the speed setting menu item For additional information on speed setting 4 refer to Code A Code B and Code C See Code A Code B and Code C on page 11 8 _ SPEED S...

Page 109: ...and 23 8 km h respectively The default s3 fwd speed is 14 8 mph 23 8 km h The s3 fwd speed may be adjusted with the handset from 11 4 to 14 8 mph 18 3 to 23 8 km h in 0 1 mph 0 16 km h increments The...

Page 110: ...a more aggressive braking action WalkAway Deterrent The walkaway deterrent menu item allows the user to turn this function ON or OFF Walkaway deterrent is triggered by the High Speed WalkAway fault Wi...

Page 111: ...9 O 67 C 80 P 68 D 81 Q 69 E 82 R 70 F 83 S 71 G 84 T 72 H 85 U 73 I 86 V 74 J 87 W 75 K 88 X 76 L 89 Y 77 M 90 Z Vehicle Date of Manufacture Four digit number programmed by vehicle manufacturer Examp...

Page 112: ...es or the current being returned to the batteries during regenerative motor braking It has a range from negative 300 amps to positive 300 amps BDI PERCENT Battery Discharge Indicator BDI Percent displ...

Page 113: ...the Forward Reverse switch in the NEUTRAL or REVERSE position the handset should indicate that the forward input is off When the Forward Reverse switch is placed in the FORWARD position the handset s...

Page 114: ...uto adjusting correction factor for estimating state of charge based upon the difference between the currently estimated state of charge and the Load Line SOC Open Circuit Voltage Start Open Circuit V...

Page 115: ...ys amp hours removed from batteries since trip amp hours was reset See Reset Trip Amp Hours on page 11 8 Trip Regen Amp Hours Displays amp hours returned to the batteries from regenerative braking sin...

Page 116: ...ons or locations where a problem with vehicle performance has been reported See following WARNING WARNING The vehicle operator should not monitor the handset while the vehicle is in motion A technicia...

Page 117: ...t is detected the controller responds to the fault by limiting the vehicle speed to 1 2 of its normal top speed If the technician reaches the conclusion that the vehicle is running slowly because batt...

Page 118: ...to a stop OVERVOLTAGE A B G Vehicle slows and beeps LOW BATTERY VOLTAGE E Top speed is reduced THERMAL CUTBACK E Top speed is reduced MOTOR STALL J None MAIN DROPOUT 1 and 2 A C Vehicle comes to a sto...

Page 119: ...condition clears SPEED SENSOR When condition clears MAIN WELDED When condition clears MAIN DRIVER ON When condition clears MAIN DRIVER OFF When accel pedal is cycled MAIN COIL OPEN When accel pedal i...

Page 120: ...ult What it means If the voltage seen by the controller coming out of the MCOR is not within specified limits this fault occurs and the controller de energizes the solenoid coil Perform additional dia...

Page 121: ...he key switch and or the FNR is switched on This is a safety control and the controller must see the pedal engaged last in the following sequence key switch first FNR second and then pedal last What t...

Page 122: ...to the motor a speed sensor fault is detected What it means Speed sensor is not working Check connection What to do Replace speed sensor MAIN DRIVER ON If the field effect transistor FET that control...

Page 123: ...is registered What to do In most cases this is an operator issue holding the vehicle on an incline with the accelerator pedal not the brake pedal See following NOTE NOTE In rare cases it could be a c...

Page 124: ...ars in the fault history menu the trained technician should attempt to determine when and where the fault has occurred For example if the motor stall fault is present in the fault history the trained...

Page 125: ...add a ready made folder from the Parameters or Monitor menu the folder icon will appear in the Favorites menu with a star on it Although you can rename a ready made folder you are not allowed to rena...

Page 126: ...to Yes Text for save as When you create a new cpf file the field at the top of the keyboard screen is either blank No text or is automatically filled with the date and time in this format YYYY_MM_DD_H...

Page 127: ...olors for specific variables use the Move Down and Move Up softkeys to achieve the desired combinations Use the left arrow key to return to the Plot Log menu To open the plotting program highlight Plo...

Page 128: ...ee Backlight under HHP Settings menu Controller is in power down mode vehicle unused and not charged for 72 hours Connect charger or drive the vehicle a short distance and reconnect the handset to the...

Page 129: ...result in vehicle malfunction property damage personal injury or death Index of Test Procedures 1 Handset Cord 2 Handset Cord Adaptor 3 CDT Ports TEST PROCEDURE 1 Handset Cord See General Warnings on...

Page 130: ...Warnings on page 1 2 3 Check the CDT port mounted under the instrument panel 3 1 Remove the three screws 1 that secure the instrument panel assembly 2 to the dash assembly 3 Figure 11 3 Page 11 28 3...

Page 131: ...nect the vehicle batteries positive cable first 4 3 5 If the handset functions when connected directly to the controller the adapter plug or vehicle wire harness should be thoroughly tested See Test P...

Page 132: ...Pagination Page 11 Connection Tests CONTROLLER DIAGNOSTIC TOOL CDT Page 11 30 2019 Precedent Villager 2 Maintenance and Service Manual...

Page 133: ...ow state of charge warning and 2 Charging confirmation The charge indicator light is controlled by pin 11 of the controller Battery Low State of Charge Warning The light comes on and remains solid whe...

Page 134: ...motor acts as a generator slowing the vehicle as it creates energy that is used to charge the batteries Tow Run Switch When the Tow Run switch is in the RUN position the vehicle will function normally...

Page 135: ...LE EXCEL SYSTEM TROUBLESHOOTING Battery Wiring Diagram 12 BATTERY WIRING DIAGRAM WD_6x8V_Batteries_ERIC_Charging Figure 12 1 Battery Wiring Diagram 2019 Precedent Villager 2 Maintenance and Service Ma...

Page 136: ...Locations ELECTRIC VEHICLE EXCEL SYSTEM TROUBLESHOOTING SONIC WELD FUSE AND 10K OHM RESISTOR LOCATIONS 2783 Figure 12 2 Sonic Weld and 10k Ohm Resistor Locations Approximate Page 12 4 2019 Precedent V...

Page 137: ...is unavailable the technician should proceed to Troubleshooting Guide 2 TROUBLESHOOTING GUIDE 1 The following troubleshooting guide is intended for use with an CDT handset See following NOTE NOTE Bef...

Page 138: ...disconnected 16 pin connector at speed controller or broken wire Repair and or connect the 16 pin connector to the speed controller Monitor Menu FORWARD INPUT and or REVERSE INPUT does not indicate th...

Page 139: ...ge 1 2 Reconnect the batteries and see if the symptom returns Diagnostic Menu MAIN DRIVER ON or MAIN DRIVER OFF fault code Failure of the FET that controls the solenoid coil Replace the speed controll...

Page 140: ...SHOOTING GUIDE 2 In the event that the vehicle is not functioning properly after completing Troubleshooting Guide 1 use Troubleshooting Guide 2 If an CDT handset is unavailable use Troubleshooting Gui...

Page 141: ...cker switch Test Procedure 6 Forward Reverse Rocker Switch on page 12 17 Solenoid loose wires Test Procedure 7 Solenoid Activating Coil on page 12 19 Solenoid failed coil Test Procedure 7 Solenoid Act...

Page 142: ...e it does not maintain speed nor accelerate MCOR malfunction Test Procedure 11 MCOR Voltage on page 12 22 Vehicle reaches top speed before 100 pedal travel is reached Speed controller failed throttle...

Page 143: ...icle without the cover properly installed Do not direct a water stream in area of the cover TESTING BASICS To use the CDT the Tow Run switch must be in the RUN position The Tow Run switch provides pow...

Page 144: ...f Test Procedures 1 Batteries Voltage Check BPV 2 48 Volt Battery Pack Voltage Under Load 3 Tow Run Switch 4 15 Amp Fuse 5 Key Switch and MCOR Limit Switch Circuit 6 Forward Reverse Rocker Switch 7 So...

Page 145: ...d probe on the positive post of battery no 1 and the black probe on the negative post of battery no 6 Figure 12 3 Page 12 13 3 The multimeter should indicate at least 48 volts If not check for loose b...

Page 146: ...ing while under load provides a more accurate diagnosis of the condition of the batteries When the discharge machine is ON it places the battery pack under load and many times can help determine if on...

Page 147: ...Basics on page 12 11 2 Access the Tow Run switch but do not disconnect wires 3 With the Tow Run switch in the RUN position 3 1 The pink wire should show BPV coming to the switch 3 2 The light green wi...

Page 148: ...the following procedure Key Switch and MCOR Limit Switch Circuit Test without the CDT Handset If the key switch functions as described proceed to the following step See following NOTE NOTE The key swi...

Page 149: ...INPUT Remove floormat and cover plate to access the MCOR See Pedal Group Removal on page 5 4 6 1 With the key switch in the ON position With an insulation piercing probe check voltage of the blue wir...

Page 150: ...rward Reverse switch in each position 4 1 Orange Wire The orange wire provides power to the switch and should show BPV coming to the switch in all three positions If the orange wire does not show BPV...

Page 151: ...actory installed solenoids Figure 12 6 Page 12 19 If not replace the solenoid A reading of 180 to 190 ohms should be obtained for service replacement solenoids Figure 12 7 Page 12 19 If not replace th...

Page 152: ...ift the rear of the vehicle with a chain hoist or floor jack Position jack stands under the frame rails just forward of each spring mount See WARNING Lift only one end in General Warnings on page 1 2...

Page 153: ...ion 2 Remove electronics module cover See Electronics Module Cover Removal Section 13 Page 13 5 3 Check 15 amp fuse See Test Procedure 4 15 Amp Fuse on page 12 15 4 Check power Using a multimeter set...

Page 154: ...OFF position for the duration of this test 2 Connect the CDT to the vehicle 3 Access the Monitor menu and select THROTTLE by using the SCROLL DISPLAY buttons 4 The CDT should indicate 0 with the pedal...

Page 155: ...e to the three pin connector at the MCOR The reading should be approximately 4 65 volts 5 If reading is zero volts check the white wire continuity from the three pin connector at the MCOR to the 16 pi...

Page 156: ...ch in the NEUTRAL position 2 Connect the CDT to the vehicle 3 Access the Monitor menu and select SPEED PULSES by using the SCROLL DISPLAY buttons The CDT should indicate OFF when the vehicle is at res...

Page 157: ...6 6 x 8 Volt battery set negative post and place the red probe with insulation piercing probe on the green wire between the three pin connector and the motor speed sensor 6 1 Raise one rear wheel off...

Page 158: ...1 4 4 3 Check continuity on A1 and A2 motor terminal posts and continuity of the F1 and F2 motor terminal posts Also check continuity of all motor wires Section 16 Electric Vehicle Motor TEST PROCEDUR...

Page 159: ...rminals until they are firmly seated in the 16 pin connector After each terminal has been pushed into the housing gently pull on the wire to ensure it is locked into place 3 Check wires in the plug to...

Page 160: ...the following information What function the wire performs Whether or not the 16 pin connector must remain connected during the test The appropriate test result for each pin If results differ from tho...

Page 161: ...BACK PROBE TO TEST TEST PROCEDURE THROTTLE OUTPUT Pin 1 White Supplies approximately 5 volts in MCOR 3 pin circuit Yes 4 to 5 volts measured between pin 1 and B terminal on controller Key switch eith...

Page 162: ...tage 8 1 If the voltage reading is correct replace the reverse buzzer 8 2 If reading is zero volts check orange white wire continuity and connection at Pin 7 in 16 Pin connector 8 3 If there is no con...

Page 163: ...9 Page 12 31 and pin 3 purple white wire of the 16 pin connector It should indicate continuity If not check sonic welds no 1 and no 2 3 Probe pin 2 red white wire It should show BPV If not check 2 am...

Page 164: ...Pagination Page 12 Test Procedures ELECTRIC VEHICLE EXCEL SYSTEM TROUBLESHOOTING Page 12 32 2019 Precedent Villager 2 Maintenance and Service Manual...

Page 165: ...el push down on the retaining tabs surrounding the key switch 4 and remove the key switch cap 8 Hold the key switch and remove the switch retaining nut 6 from the outside of the instrument panel Figur...

Page 166: ...ischarge the controller See Disconnecting the Batteries Electric Vehicles on page 1 4 2 Remove instrument panel See Key Switch Removal on page 13 1 3 Disconnect the wires at the warning light 4 Press...

Page 167: ...ge 12 17 FORWARD REVERSE ROCKER SWITCH REMOVAL 1 Disconnect the batteries and discharge the controller See Disconnecting the Batteries Electric Vehicles on page 1 4 2 Remove two screws 2 that hold For...

Page 168: ...2 3 N m 4 Place the Tow Run switch in the TOW position and connect the batteries See Connecting the Batteries Electric Vehicles on page 1 4 5 Place the Tow Run switch in the RUN position 6 Inspect th...

Page 169: ...ery bucket CAUTION Be careful not to break the two hooks 4 on the bottom of the cover Push the bottom of the cover up to release the hooks before pulling cover away from battery bucket ELECTRONICS MOD...

Page 170: ...Run switch 2 See Electronics Module Cover Removal on page 13 5 3 Remove Tow Run switch boot hex nut 1 Figure 13 6 Page 13 7 4 Remove Tow Run switch 2 from electronics module and disconnect the pink wi...

Page 171: ...4 Remove the T25 torx screw securing the MCOR to the pedal group 5 Detach the two tabs from the accelerator pedal and remove the MCOR from vehicle MCOR INSTALLATION 1 Align the two tabs of the MCOR 2...

Page 172: ...es from reverse buzzer 4 Remove the two screws from the reverse buzzer Remove the reverse buzzer from the dash panel REVERSE BUZZER INSTALLATION 1 Install the reverse buzzer in the reverse order of re...

Page 173: ...14 5 3 Remove the bolt 2 that secures the electronics module 3 to the battery bucket 4 Pull electronics module 3 forward and disconnect the heavy gauge wires from the controller 1 and solenoid 4 5 Dis...

Page 174: ...rn electronics module 3 to its location in vehicle but leave it tilted forward 2 Complete connections to the controller 1 the Tow Run switch 5 and the solenoid 4 per the electrical schematics 3 Tighte...

Page 175: ...nd A2 Motor Voltage on page 12 25 SPEED CONTROLLER REMOVAL 1 Disconnect the batteries and discharge the controller 1 See Disconnecting the Batteries Electric Vehicles on page 1 4 2 Remove the electron...

Page 176: ...on and verify the value is 13 or higher If not contact a Club Car Technical Representative 7 8 Place the Tow Run switch in the TOW position for 30 seconds Then return it to RUN 8 Inspect the vehicle f...

Page 177: ...e show signs of corrosion or the plug is difficult to insert or remove the receptacle contacts and plug terminals should be cleaned with a good electrical contact cleaner or lightly sprayed with WD 40...

Page 178: ...lenoid Tighten nut 72 to 84 in lb 8 to 9 5 N m 5 Connect 10 gauge black wire to controller B terminal Tighten bolt to 108 in lb 12 2 N m 6 Connect light blue wire to main harness at bullet connector w...

Page 179: ...ll a physician immediately WARNING Wear safety glasses or approved eye protection when servicing the vehicle or battery charger Wear a full face shield and rubber gloves when working on or near batter...

Page 180: ...of batteries i e terminal posts Poor fair or proper cleanliness of batteries Added electric accessories Use of a single point watering system SPWS MEASURING VOLTAGE OF BATTERY SET Set the multimeter...

Page 181: ...specific to the battery installed Regrouping is now Club Car s standard battery replacement method Regrouping is the practice of placing batteries of similar condition together in one vehicle For exam...

Page 182: ...14 Battery Regrouping ELECTRIC VEHICLE BATTERIES 3104 Figure 14 2 Battery Regrouping Process Flow Page 14 4 2019 Precedent Villager 2 Maintenance and Service Manual...

Page 183: ...bilities until they have been discharged and recharged 50 to 70 times To obtain the maximum service life from new batteries restrict vehicles with new batteries to one hour of operation between charge...

Page 184: ...the usage frequency of the membrane can also contribute to the filtered water quality Due to the variance in water quality consistency Club Car recommends the use of the deionizer or distilled water...

Page 185: ...er properly 2 The battery hold downs should be tight enough so that the batteries do not move while the vehicle is in motion but not so tight as to crack or buckle the battery case For 8 volt batterie...

Page 186: ...on follow this maintenance program on a regular basis 1 Keep the batteries clean and free of corrosion Wash tops and terminals of batteries with a solution of baking soda and water use 1 cup 237 mL ba...

Page 187: ...t least 1 2 inch 13 mm above plates to 1 4 inch 6 mm below level indicator 17 Figure 14 3 Battery Electrolyte Level Add water only after charging unless the electrolyte is below the level of the plate...

Page 188: ...ter with hand pump Club Car Part Number 104006101 is recommended for private consumer applications INITIAL MAINTENANCE OF THE SPWS After six weeks of operation remove the valves from the batteries and...

Page 189: ...ch use provided the charge cycle will not be interrupted and the charger will be allowed to shut off automatically Placing the batteries on charge after each use reduces the depth of discharge and pro...

Page 190: ...Pagination Page 14 Early Excessive Discharging ELECTRIC VEHICLE BATTERIES Page 14 12 2019 Precedent Villager 2 Maintenance and Service Manual...

Page 191: ...not connect a stationary charger to the receptacle if the charger cord plug or the vehicle receptacle is broken damaged or does not make a good electrical connection Fire or personal injury can result...

Page 192: ...Returned charge termination Communication Display Module CDM is not used Only an CDT is needed for data The CDT will remain ON when the charger is connected Only PD 8 volt batteries are approved for u...

Page 193: ...charger has a USB port for use by Club Car authorized technicians for data transfer reconfiguration and updates Keep the USB port cover in place when the port is not in use See USB Service Port Clean...

Page 194: ...e 85 to 270 VAC range the charger will not operate THERMAL CUTBACK The charger operates at full power in ambient temperatures between 40 F 40 C and 104 F 40 C The charger also will function outside of...

Page 195: ...e Battery pack is fully charged Flashing green Solid green Charging is in progress Battery pack has reached a high state of charge Off Flashing green Charging is in progress Battery pack has NOT reach...

Page 196: ...igure 15 2 Position the charger so that is has adequate ventilation and the charger status indicator panel is visible The charger can be mounted in any orientation right side up upside down etc provid...

Page 197: ...applicable electrical codes for the location Connect the charger AC supply cord to a properly grounded three wire outlet within the voltage and frequency range shown on the charger Do not use an adapt...

Page 198: ...ounding type plug The AC plug must be connected to an appropriate receptacle that is properly installed and grounded in accordance with the National Electrical Code and all local codes and ordinances...

Page 199: ...oo loose or does not make a good connection The plug and receptacle feel hotter than normal during charge The plug pins or receptacle contacts are bent or corroded The plug receptacle or cords are cut...

Page 200: ...The charger will turn on two to five seconds later after the charger interlock function activates The charger interlock remains activated and prevents operation of the vehicle until the DC cord is dis...

Page 201: ...and the USB port clean and dry Keep all cooling fins clean If the detachable input power supply cord set is damaged replace with a cord that meets the following criteria _ For North America UL or CSA...

Page 202: ...charge status light doubles as the USB light Flashing green means data transfer from the USB is occurring Solid green means data transfer is complete Use the USB service port for charging algorithm u...

Page 203: ...aused by a temporary situation To reset charger power take the following steps 1 Unplug the DC cord from the vehicle 2 Unplug the AC cord from the AC power source 3 Wait for the red light to go off wa...

Page 204: ...connect and at tempt to charge again 2 AC power supply was shut off Verify AC power is present and charge again See AC Power and Continuity Test of AC Circuit on page 15 17 3 AC circuit breaker is tri...

Page 205: ...ower and Continuity Test of AC Circuit on page 15 17 7 Ambient temperature too hot above 104 F 40 C Check for dirty obstructed or damaged cooling fins Clean if necessary and ensure sufficient cooling...

Page 206: ...ify that the 10 gauge red wire from the charger receptacle is connected to the large post of solenoid with 6 gauge red wire Figure 15 5 Page 15 8 3 2 Verify that the 10 gauge black wire from the charg...

Page 207: ...The on charge voltage for the set should be between 56 0 volts and 63 0 volts depending on the age and state of charge of the batteries being tested Old batteries may have enough capacity left to las...

Page 208: ...zzer to sound three times See following NOTE NOTE The number of flashes and beeps can vary depending on the Beep Option setting See Beep Option Section 11 Page 11 8 With a Meter A clamp meter can be u...

Page 209: ...AC cord from the AC outlet NOTE This charger has no internals to service or repair It only has a few external repairs that can be performed If an internal component needs repair the charger must be re...

Page 210: ...ef 6 to charger 4 Remove terminal block cover 3 See Terminal Block Cover Removal on page 15 19 5 Remove torx screw 7 securing each DC cord wire to terminal block 4 DC CORD AND STRAIN RELIEF INSTALLATI...

Page 211: ...T REMOVAL 1 Disconnect DC cord 1 from vehicle 2 Disconnect AC cord 2 from AC outlet 3 If mounted detach charger from shelf or wall 4 Squeeze barbs on back side of foot 10 and push foot out of charger...

Page 212: ...Pagination Page 15 External Charger Repairs ELECTRIC VEHICLE BATTERY CHARGER Page 15 22 2019 Precedent Villager 2 Maintenance and Service Manual...

Page 213: ...e following tests can be performed without disassembling the motor using a multimeter or continuity tester NOTE Observe the following before testing the motor This is only testing continuity Tag the m...

Page 214: ...e problems a grounded A1 or A2 terminal a grounded wire in the brush area or a grounded armature commutator An incorrect reading for the F1 or F2 terminal indicates a possible grounded F1 or F2 termin...

Page 215: ...ce the red probe on the F1 terminal and the black probe on the F2 terminal The multimeter should indicate continuity If the reading is incorrect a possible open field coil or bad connections at the te...

Page 216: ...hain hoist or hydraulic floor jack with 1000 lb 454 kg minimum lifting capacity Do not use lifting device to hold vehicle in raised position Use approved jack stands of proper weight capacity to suppo...

Page 217: ...ft in step 9 Fingers may get pinched when motor disengages 10 Carefully slide the motor away from the transaxle until the motor spline disengages the input shaft and remove the motor from the vehicle...

Page 218: ...nd cap from the motor frame using the following procedure 5 1 With the end cap bolts loose about 1 4 inch 6 3 mm between the end cap and the head of the bolt place a socket on the head of the bolt See...

Page 219: ...armature for wear and damage See Armature Inspection and Testing on page 16 8 11 Inspect the motor frame and field windings See Motor Frame and Field Windings Inspection on page 16 10 12 Remove the b...

Page 220: ...Visual Inspection Burned charred or cracked insulation Improperly cured varnish Thrown solder Flared armature windings Damaged armature core laminations Worn burned or glazed commutators Dirty or oily...

Page 221: ...mature Ground Test CAUTION Do not submerge the armature in solvent NOTE Before testing the armature wipe it clean with a clean cloth Remove any carbon dust and metal particles from between the commuta...

Page 222: ...ion do not over extend the spring Using excessive force will damage the spring 4 4 Replace springs which require a force of less than 35 ozf 0 99 kgf Figure 16 13 Page 16 11 See following NOTE NOTE Wh...

Page 223: ...wipe the carbon dust off of the bearing Inspect the bearing by spinning it by hand and checking for both axial A and radial B play Figure 16 14 Page 16 11 4 Replace the bearing if it is noisy does not...

Page 224: ...Testing and Inspection ELECTRIC VEHICLE MOTOR 10 24 23 25 4 5 6 7 9 12 8 14 13 15 16 16 11 1 2 17 18 3 30 2613 Figure 16 15 Electric Motor EJ8 4001A Page 16 12 2019 Precedent Villager 2 Maintenance a...

Page 225: ...he retaining ring to secure the bearing Figure 16 11 Page 16 8 2 Install the brushes and brush rigging See following NOTE NOTE When installing new brushes remove and replace brushes one at a time This...

Page 226: ...to support the weight of the commutator The brushes can be easily damaged by this weight 4 Gently press each brush with a small screwdriver until the spring rests on the end of each brush as shown Fi...

Page 227: ...from the end of the shaft Figure 16 21 Page 16 15 2 4 The grease should be evenly distributed in the grooves to a width of approximately 3 8 inch 9 5 mm 2 5 Use a flat screwdriver to clean the grease...

Page 228: ...ransaxle Figure 16 24 Page 16 17 Do not tighten 4 3 Begin finger tightening the bolts 1 2 and 3 in the sequence indicated Continue tightening by hand until the motor is seated in the transaxle housing...

Page 229: ...until rubber bushing expands to the diameter of the cup washer 8 If removed install wheels and finger tighten the lug nuts 9 Lift vehicle and remove jack stands Lower vehicle to the floor and tighten...

Page 230: ...Pagination Page 16 Motor Installation ELECTRIC VEHICLE MOTOR Page 16 18 2019 Precedent Villager 2 Maintenance and Service Manual...

Page 231: ...front wheels Loosen lug nuts on rear wheels and lift the rear of the vehicle with a chain hoist or floor jack Place jack stands under the axle tubes to support the vehicle See WARNING Lift only one e...

Page 232: ...l seated against the shoulder on the axle shaft 8 Inspect bearing 5 Figure 17 5 Page 17 3 If the bearing in a Type G transaxle is worn or damaged the entire axle shaft assembly 1 or 2 must be replaced...

Page 233: ...d Shaft 17 1 3 14 15 39 24 26 13 33 36 32 8 10 11 12 20 18 19 16 16 16 17 23 21 25 36 22 35 13 27 30 31 29 2 3 8 36 27 30 28 37 38 5 6 4 15 39 766 Figure 17 5 Transaxle Type G 2019 Precedent Villager...

Page 234: ...ough to the bearing on the shaft then rotate it to align the shaft splines with the splined bore of the differential side gear 27 Figure 17 5 Page 17 3 Continue advancing the shaft until the bearing o...

Page 235: ...Vehicle Supported on Jack Stands 651 Figure 17 7 Brake Cable 6 Disconnect the shock absorbers from their lower mounts Figure 17 8 Page 17 6 7 Disconnect the four motor wires Use two wrenches to preven...

Page 236: ...in on the leaf spring and slide the transaxle to the rear and out of the vehicle 15 Drain the lubricant from the transaxle and remove the axle shafts See Axle Shaft and Oil Seal Removal on page 17 1 S...

Page 237: ...ssembly 19 Lift intermediate gear assembly and differential gear case unit out simultaneously Figure 17 5 Page 17 3 See following CAUTION CAUTION Do not damage gears Use extreme care when handling the...

Page 238: ...ial pin 31 by pushing pin through differential gear case from one side Figure 17 5 Page 17 3 See also Figure 17 14 Page 17 8 8 5 Remove the idler gears 1 and 2 and thrust plates 3 and 4 Figure 17 15 P...

Page 239: ...sket on mating surface of housing 8 2 Install left half of transaxle housing 20 Figure 17 5 Page 17 3 8 3 Install bolts 24 in the case housing and tighten to 19 ft lb 25 7 N m Type G transaxles have n...

Page 240: ...ise the differential while guiding the leaf springs into the rear spring shackles Then raise the jack stands to support the transaxle 6 Connect the motor wires making sure they are connected to the co...

Page 241: ...n when the Forward Reverse switch is in the REVERSE position The reverse buzzer will sound as a warning when the Forward Reverse switch is in REVERSE Make sure that the vehicle does not operate when t...

Page 242: ...Pagination Page 17 Transaxle Installation ELECTRIC VEHICLE TRANSAXLE Page 17 12 2019 Precedent Villager 2 Maintenance and Service Manual...

Page 243: ...witch OFF and ON to reset the Low Oil Warning Light The gasoline vehicle is equipped with a low oil warning light 4 located at the top of the instrument panel If the warning light comes on oil should...

Page 244: ...difficulties should they occur The guides include the symptom probable cause s and suggested checks The procedures used in making these checks can be found in the referenced sections of the maintenan...

Page 245: ...ule If connection is made and no corrosion is present replace ECU and Throttle Module 31 Fuel Pump Open Connection Check fuel pump and fuel system Check electrical connections at ECU Throttle module a...

Page 246: ...m Throttle body dirty or improperly adjusted Clean or adjust Section 21 Gasoline Vehicle Fuel System Low cylinder compression Section 20 Gasoline Vehicle Engine Cylinder head bolts not tighten properl...

Page 247: ...FI Section 21 Gasoline Vehicle Fuel System Overloading Reduce to rated load Engine overheats Poor quality engine oil Replace Excessive carbon deposits on piston head or in combustion chamber Section 2...

Page 248: ...lenoid Accelerator pedal limit switch failed Test Procedure 7 Throttle Position Sensor TPS Key switch failed Test Procedure 5 Key Switch Start Circuit Neutral lockout limit switch failed Test Procedur...

Page 249: ...oline Vehicle Clutches Damaged drive clutch Section 23 Gasoline Vehicle Clutches Damaged starter generator pulley Section 19 Gasoline Vehicle Electrical Components Starter Generator on page 19 1 Exces...

Page 250: ...tions GASOLINE VEHICLE TROUBLESHOOTING AND ELECTRICAL SYSTEM SONIC WELD FUSE AND DIODE LOCATIONS Figure 18 1 Sonic Weld and Diode Locations Approximate Villager 2 EFI Page 18 8 2019 Precedent Villager...

Page 251: ...Circuit Engine Kill Circuit Reverse Buzzer Circuit Low Oil Warning Light Circuit Neutral Lockout Circuit Fuel Pump Circuit Fuel Gauge and Sending Unit Circuit Hour Meter Circuit Lighting Circuit Reco...

Page 252: ...oltage is accessed in Test Procedure 1 Battery on page 18 12 The MAINTENANCE OPERATE switch in the MAINTENANCE position grounds and kills the ignition if the FNR shifter is placed in FORWARD or REVERS...

Page 253: ...l Lockout Limit Switch Pedal Start Vehicles Only 11 Starter Generator Generator Function 12 Starter Generator Starter Function 13 Voltage Regulator 14 Ignition Spark 15 Ignition Coil 16 Reverse Buzzer...

Page 254: ...n be found in section Gasoline Vehicle Electrical Components on page 19 1 of this manual See Battery on page 19 31 1 Place the Forward Reverse handle in the NEUTRAL position and the neutral lockout sw...

Page 255: ...9 6 V 60 F 16 C 9 5 V 50 F 10 C 9 4 V 40 F 4 C 9 3 V 30 F 1 C 9 1 V 20 F 7 C 8 9 V 10 F 12 C 8 7 V 0 F 18 C 8 5 V 4 If the battery is found to be good or if the electrical problem continues after the...

Page 256: ...ntinuity test ATM style blade fuses are located on the main wire harness in front of the battery The ABC style glass fuse is located on the main wire harness adjacent to the ATM fuse holder 2784 Figur...

Page 257: ...page 1 2 NOTE This is a continuity test for the main ground wire s of the vehicle An additional ground wire is located on top of the fuel tank 1 If necessary see Testing Basics on page 18 10 2 Discon...

Page 258: ...STEM TEST PROCEDURE 4 EFI System ECU and Sensors See General Warnings on page 1 2 WARNING This procedure involves testing voltage resistance and continuity If necessary see Testing Basics on page 18 1...

Page 259: ...Red White and Ground Battery Voltage Plug connected to ECU and Key ON 13 Gray MAP Sensor Input Voltage ECU Gray Pin 13 Green Yellow and Ground Approx 3 9 volts sea level engine OFF 3 0 volts engine r...

Page 260: ...CU Black Pin 9 Red and ECU Black Pin 10 Black Battery Voltage Key ON Continuity ECU Black Pin 10 Black and Ground Meter should beep Key OFF 10 Black Ground for ECU Power Voltage ECU Black Pin 10 Black...

Page 261: ...solenoid and the 4 pin connected car plug If it does not show battery voltage the switch has failed OPEN and must be replaced TEST PROCEDURE 6 Key Switch Engine Kill Circuit See General Warnings on pa...

Page 262: ...ally open NO portion of the circuit used to energize the starter solenoid NOTE Keep the battery connected while performing this test procedure 1 Place the neutral lockout switch in the MAINTENANCE pos...

Page 263: ...park plug 4 With battery connected and using a multimeter set to the diode test function attach the red lead to the negative battery terminal and the black lead to the white black wire at the limit sw...

Page 264: ...reading is not within limits replace the solenoid 4 Contact Side Remove the heavy gauge white wire and 16 gauge red wire from the large post of the solenoid Figure 18 4 Page 18 22 Do not allow the wi...

Page 265: ...y between terminals T2 and T3 4 With switch in position 2 OPERATE 4 1 Check for no continuity between terminals T2 and T3 4 2 Check for continuity between terminals T1 and T2 T1 T3 T2 2 1 1 Position 1...

Page 266: ...switch as the Forward Reverse shifter is being shifted The limit switch should make an audible click as it is pressed If it does not check for wear on the cam lobe and replace shift lever if necessary...

Page 267: ...ld show the voltage rising on the meter If the voltage rises above 15 3 volts DC test the voltage regulator See Voltage Regulator on page 18 27 If the voltage does not rise a tear down inspection of t...

Page 268: ...eading is incorrect it indicates a possible grounded F1 or F2 terminal or a grounded field coil If the DF reading is incorrect it indicates a possible grounded DF terminal or a grounded field coil 4 U...

Page 269: ...ing the engine Using a multimeter set to 20 volts DC place the red probe on the large post of the solenoid with the red wire from the voltage regulator attached Place the black probe on the negative b...

Page 270: ...Small Engine Setting on the Thexton 404 tool Connect the tester to the spark plug wire and connect the alligator clip to a solid engine ground 3 2 Start the engine There should be a strong blue spark...

Page 271: ...y keep the new coil in the circuit NOTE Resistance value ranges given in these tests reflect a tolerance of 40 Please note that these values are rough standard and it is impossible to reach an exact c...

Page 272: ...een the black wire and ground With Forward Reverse handle still in the FORWARD position there should be no continuity If either reading is incorrect replace limit switch See Reverse Buzzer Limit Switc...

Page 273: ...ected while performing this test procedure 1 If necessary see Testing Basics on page 18 10 2 Place the Forward Reverse handle in the NEUTRAL position and the neutral lockout switch in the MAINTENANCE...

Page 274: ...inals Voltage to Pump 1 If necessary see Testing Basics on page 18 10 2 Disconnect the 5 pin connector from the top of the fuel pump module 3 Check that battery voltage is present between ground and t...

Page 275: ...2 Page 18 32 5 The following resistance readings in ohms should be obtained depending on the position of the float inside the fuel tank The resistance reading will vary according to the exact position...

Page 276: ...continuity of the blue and black wires Figure 18 13 Page 18 34 7 The orange wire should remain disconnected for this step With the black probe still on the black wire terminal of the fuel gauge place...

Page 277: ...ock the wheels 2 Turn the key switch to ON and record the current hour meter reading 3 Press and hold the accelerator pedal to run the engine for at least six minutes the meter records in six minute i...

Page 278: ...ds no 4 10 and 14 3 Probe pin 2 red wire It should show battery voltage with the key switch in the ON position If not check 2 amp fuse near ATM fuse holder See following NOTE NOTE The red wire only ha...

Page 279: ...r so that when the pivot bolts 5 are removed the starter generator will not fall Remove the two pivot nuts 7 and bolts 5 from the mounting bracket 7 Remove the starter generator DISASSEMBLY OF THE STA...

Page 280: ...re 19 3 Page 19 2 0 1 1 2 1 2 Figure 19 3 Inspect Brushes and Measure Length BRUSH SPRING INSPECTION AND REPLACEMENT 1 Visually inspect springs Replace all four springs if any spring is discolored fro...

Page 281: ...le damage to the brushes lift the brush springs and pull the brushes back from the center of the commutator end cover The springs will rest on the sides of the brushes and help prevent them from slidi...

Page 282: ...sembly from the field coil housing first remove the two securing bolts 43 Carefully remove armature and output end cover assembly from the field coil housing so components are not damaged 3 To separat...

Page 283: ...and radial B play Figure 19 7 Page 19 5 2 Replace the bearing if it is noisy does not spin smoothly or has excessive play Check the bearings and replace if rusted worn cracked or if there is an abnor...

Page 284: ...ainst armature shaft 7 Use bearing puller if a press is not available 494 Figure 19 8 Bearing Removal FIELD COIL ASSEMBLY Replace entire field coil housing assembly if coils pole shoes or terminals ar...

Page 285: ...tator can be polished away with 400 grit or finer sandpaper See following CAUTION CAUTION Do not use emery cloth on the commutator Particles of emery are conductive and may short circuit the commutato...

Page 286: ...efore testing wipe the armature with a clean cloth and remove carbon dust and metal particles from between commutator bars Using a multimeter set on 200 ohms place the positive probe on the commutator...

Page 287: ...RTER GENERATOR REWORK Any rework must be performed by a qualified technician Starter generator service specifications are listed in the following table _ ITEM SERVICE LIMIT Commutator diameter minimum...

Page 288: ...ards the center of the cover Figure 19 5 Page 19 4 6 Install the commutator end cover 23 onto the armature shaft Use the tapped mounting holes to align housing to the cover rotate and orient as shown...

Page 289: ...ter Generator 19 1 2 F1 DF 3 90 F2 1 Jumper Wire 2 1 inch 25 4 mm Minimum Radius 3 Jumper Wire Not Allowed in this Area 2687 Figure 19 12 A1 to F1 Terminal Jumper Wire Routing 2019 Precedent Villager...

Page 290: ...et 3 and then through the starter generator Install a lock washer 6 and nut 4 onto adjustment bolt 1 finger tight Figure 19 13 Page 19 12 4 Install starter generator belt 2 and adjust belt tension as...

Page 291: ...belt is tensioned varies between a used and new belt EFI engines have higher starting torque demands that require consistent belt tension to prevent slipping Belt tension should be checked periodicall...

Page 292: ...Figure 19 13 Page 19 12 6 Install belt tension tool 6 1 Carefully insert pry bar between starter generator and bracket 6 2 Carefully lift starter up until tension tool can be installed as shown over t...

Page 293: ...ne Ensure clearance between F2 terminal and starter generator bracket before starting engine 8 4 Engage starter and crank engine a minimum of 5 seconds and a maximum of 15 seconds to fully seat the be...

Page 294: ...ulator three pin connector 3 to the wire harness 3 Connect battery and spark plug wire s See Connecting the Battery Gasoline Vehicles on page 1 3 4 Place Forward Reverse handle in NEUTRAL and place th...

Page 295: ...OL UNIT REMOVAL 1 Disconnect battery See Disconnecting the Battery Gasoline Vehicles on page 1 3 2 Remove ECU mounting plate bolts 3 Disconnect gray and black wire connectors ENGINE CONTROL UNIT INSTA...

Page 296: ...ure 19 19 Page 19 18 2 2 Rotate the instrument panel up and away from the dash to disengage the tabs at the top of the instrument panel 2 3 Disconnect the electrical connector 3 to the instrument pane...

Page 297: ...ttery and spark plug wire s See Connecting the Battery Gasoline Vehicles on page 1 3 MAINTENANCE OPERATE SWITCH TESTING THE MAINTENANCE OPERATE SWITCH See Test Procedure 9 Maintenance Operate Switch P...

Page 298: ...switch 1 located on the transaxle 4 Remove two nuts 3 and washers 4 from the neutral lockout limit switch 1 and slide the limit switch off of the screws NEUTRAL LOCKOUT LIMIT SWITCH INSTALLATION 1 In...

Page 299: ...in lb 1 6 N m 2 Connect the ring terminal with the 10 gauge white wire and the 16 gauge red wire on a large post on the solenoid 3 Connect the ring terminal with the two 10 gauge red wires to the oth...

Page 300: ...s Only Remove fuse holder cover ABC Fuse Only Open in line fuse holder 3 Remove the fuse FUSE INSTALLATION 1 Install the fuse See following WARNING WARNING If a fuse is blown determine the cause of th...

Page 301: ...The kill limit switch is housed inside the throttle position sensor The throttle position sensor itself is not intended to be replaced If sensor is determined to need replacing through test procedures...

Page 302: ...Install the instrument panel 4 1 Connect the electrical connector 3 Figure 19 19 Page 19 18 4 2 Position the instrument panel 2 on the dash assembly Make sure tabs on upper edge properly engage with t...

Page 303: ...4 and washers 5 from the reverse buzzer switch 3 and slide the reverse buzzer switch off of the screws 2 REVERSE BUZZER LIMIT SWITCH INSTALLATION 1 Install the reverse buzzer limit switch 3 with two s...

Page 304: ...19 Reverse Buzzer Limit Switch GASOLINE VEHICLE ELECTRICAL COMPONENTS 2 3 1 5 4 Figure 19 22 Reverse Buzzer Limit Switch Page 19 26 2019 Precedent Villager 2 Maintenance and Service Manual...

Page 305: ...w Oil Warning Light LOW OIL WARNING LIGHT INSTALLATION 1 Push a new unit into hole in instrument panel until plastic tabs engage Figure 19 23 Page 19 27 2 Connect yellow and yellow white wires from th...

Page 306: ...he fuel gauge and remove the gauge from the instrument panel 3 5 4 2 BLACK ORANGE BLUE Bracket 5 may vary in appearance 2437 Figure 19 24 Fuel Gauge Installation FUEL GAUGE INSTALLATION 1 Install a ne...

Page 307: ...uel pump module TESTING THE FUEL LEVEL SENDING UNIT See Test Procedure 21 Fuel Level Sending Unit on page 18 33 HOUR METER See General Warnings on page 1 2 The hour meter displays the number of hours...

Page 308: ...SOR See General Warnings on page 1 2 TESTING THE OIL LEVEL SENSOR See Test Procedure 18 Oil Level Sensor on page 18 31 OIL LEVEL SENSOR REMOVAL See Oil Level Sensor Removal on page 20 12 OIL LEVEL SEN...

Page 309: ...jumper cables GENERAL INFORMATION See preceding DANGER and WARNING statements Gasoline vehicles are equipped with a 12 volt top post battery When changing a 12 volt battery in any gasoline powered veh...

Page 310: ...See Vibration Damage on page 19 32 SELF DISCHARGE Dirt and battery acid can provide a path for a small current draw that slowly discharges the battery To prevent self discharge the battery should alwa...

Page 311: ...tery post 4 The battery may be charged with a slow charge 3 to 10 amps or a fast charge 20 to 30 amps Charge until the battery voltage is greater than 12 4 volts See following WARNING WARNING If the b...

Page 312: ...en or the container is bulged discard battery A frozen battery can explode 6 The frequency of recharging required depends on the temperature of the storage area but it is recommended that the battery...

Page 313: ...ession using a standard compression tester Low compression would normally indicate a problem in the cylinder assembly such as defective rings gaskets etc Compression should be At a normal cranking spe...

Page 314: ...ver screws M6 25 in lb 2 8 N m Bolts marked with 4 when used with nuts M8 M6 M5 130 in lb 15 N m 50 in lb 5 9 N m 30 in lb 3 4 N m ADJUSTMENTS AND SETTINGS _ ITEM VALUES Spark plug gap 0 024 to 0 028...

Page 315: ...e 20 1 Engine Oil Level Check Engine Oil Change Engine oil should be changed after the first 100 hours of operation After that it should be changed every 200 hours of operation or annually whichever c...

Page 316: ...oil drain plug and oil drain pan 6 Clean the oil drain plug threads with solvent to remove oil and oil residue Make sure that the compression washer remains on the drain plug 7 Use a 14 mm socket or...

Page 317: ...atchet or spark plug wrench to loosen the plug Spark Plug Cleaning Inspection and Repair Examine the plug Figure 20 4 Page 20 6 The deposits on the plug base and electrode are an indication of the cor...

Page 318: ...sary Use a high temperature anti seize lubricant on the threads of the spark plug to reduce friction when installing a new plug and reduce gauling and thread seizing for future replacements Install th...

Page 319: ...ut 2 and turn the adjuster 3 up or down to adjust the clearance to 0 0047 in 0 12 mm for both intake and exhaust Once clearance is correct tighten the lock nut 2 to 52 in lb 6 N m 6 After adjusting va...

Page 320: ...NE VEHICLE ENGINE ENGINE REMOVAL ENGINE REMOVAL 11 18 9 8 3 5 6 19 20 17 4 7 10 11 14 16 13 12 15 14 21 2 3036a Figure 20 7 EX40 Engine and Mounting Brackets Page 20 8 2019 Precedent Villager 2 Mainte...

Page 321: ...oil properly 11 If replacing engine 1 remove starter generator mounting weldment 10 and retain for installation on new engine See following NOTE NOTE If replacing engine and throttle body the ECU must...

Page 322: ...en P clamp bolts to 36 in lb 4 0 N m 14 Check all hardware for proper torque tightness 15 Fill engine to proper level with correct type of oil See Engine Oil Gasoline Vehicle Section 20 Page 20 2 CAUT...

Page 323: ...N The flywheel nut has right hand threads Turn it clockwise to tighten or counterclockwise to loosen Do not damage the fan blades with the strap wrench Do not place screwdriver or pry bar in the fan b...

Page 324: ...lowing CAUTION CAUTION The flywheel nut has right hand threads Turn it clockwise to tighten or counterclockwise to loosen Be careful not to damage the fan blades Use a strap wrench to hold flywheel Do...

Page 325: ...n to 80 in lb 9 N m Figure 20 11 Page 20 13 3 Connect oil level sensor wire 3 to wire harness 4 Secure oil sensor wire 3 with clamp 2 and bolt 1 Tighten bolt to 80 in lb 9 N m 5 Install flywheel and f...

Page 326: ...012 Inch 0 304 mm 6 510 Figure 20 12 Ignition Coil 512 Figure 20 13 Adjust Ignition Coil Air Gap IGNITION COIL INSTALLATION 1 Position ignition coil 11 onto engine and tighten two mounting bolts 10 f...

Page 327: ...20 15 2 Remove the two bolts 3 and two lock nuts 4 securing the snubber bracket 5 to the engine pan 1 3 Slide snubber 2 and bracket 5 assembly toward battery to remove it from vehicle 4 Slide snubber...

Page 328: ...Pagination Page 20 Snubber GASOLINE VEHICLE ENGINE Page 20 16 2019 Precedent Villager 2 Maintenance and Service Manual...

Page 329: ...Absolute Pressure MAP sensor engine block temperature sensor and ignition timing EFI SYSTEM FEATURES SPECIFICATIONS NOTE This manual covers ECU software version F6i33051 The ECU and throttle body fue...

Page 330: ...FUEL SYSTEM 2 3 1 5 6 7 4 1 ECU 2 Fuel Pump 3 Fuel Tank 4 Fuel Injector 5 MAP Sensor 6 Engine Temperature Sensor 7 CDI Ignition Unit 3040 Figure 21 1 EFI System Components Page 21 2 2019 Precedent Vi...

Page 331: ...e fuel in an approved fuel container Keep the fuel container in a ventilated area away from sparks and heat sources Fuel is flammable and explosive To avoid electric arc caused by static electricity t...

Page 332: ...livery system without first depressurizing the system will result in a sudden release of pressurized gasoline at the connection To prevent possible serious injury or death fuel pressure must be reliev...

Page 333: ...e key switch to the OFF position and remove the key place the Forward Reverse handle in the NEUTRAL position and chock the wheels 2 Disconnect battery See Disconnecting the Battery Gasoline Vehicles o...

Page 334: ...two flange nuts 7 and slide air intake adapter 3 bracket 4 gaskets 8 insulator 9 and throttle body 1 off threaded studs 8 9 8 8 4 8 2 3 6 7 5 1 3041 Figure 21 3 Throttle Body Exploded View Page 21 6 2...

Page 335: ...on 21 Page 21 24 9 If equipped install air deflector on top of engine 10 Clean spilled and remove any drained gasoline from the area 11 Connect battery See Connecting the Battery Gasoline Vehicles on...

Page 336: ...ct battery cables negative cable first Disconnect the spark plug wire from the spark plug See Disconnecting the Battery Gasoline Vehicles on page 1 3 GENERAL INFORMATION For proper vehicle operation i...

Page 337: ...ge 1 3 3 At engine 3 1 If equipped remove air deflector from top of engine 3 2 Disconnect Z fitting of governor cable 1 from throttle lever 2 Figure 21 5 Page 21 9 3 3 Unsnap governor cable 1 from thr...

Page 338: ...and throttle stop screw 7 to 0 055 in 0 039 1 4 mm 1 as shown Figure 21 7 Page 21 10 Tighten stop screw jam nut 6 to 36 in lb 4 0 N m 9 Check engine RPM adjustment See Engine RPM Adjustment on page 2...

Page 339: ...ole in the frame and feed it towards the pedal group Connect the accelerator cable to the pedal group See Pedal Group Gasoline Vehicle on page 5 4 2 2 Separate jam nuts 9 on cable and place threaded e...

Page 340: ...lated Ground speed is easily determined by a known distance travelled divided by the amount of time it took to travel that known distance Rate Distance Time 1 Establish a known distance to travel exam...

Page 341: ...edures 5 1 To reduce RPM adjust the two jam nuts 9 to move the accelerator cable housing toward the rear of the vehicle until specified ground speed is reached Figure 5 4 Page 5 5 See Section 2 Vehicl...

Page 342: ...a Figure 21 9 Air Intake System Villager 2 with EFI AIR FILTER The air filter should be checked every year or 100 hours More frequent service may be required in extremely dirty operating environments...

Page 343: ...ON CAUTION Engine damage will occur if the air filter cover is not properly secured If air cleaner is extremely dirty clean thoroughly Use only Club Car replacement air filters or equivalent The use o...

Page 344: ...fire hazard Improper orientation of the hose clamp 5 may result in fuel tank damage Figure 21 11 Page 21 16 1 Position air cleaner 1 inside the fuel bucket Figure 21 9 Page 21 14 Secure with screws 2...

Page 345: ...nto hot engine See Relieving Fuel Pressure on page 21 4 FUEL LINE REMOVAL 1 Turn the key switch to the OFF position and remove the key place the Forward Reverse handle in the NEUTRAL position and choc...

Page 346: ...e on top of fuel pump module 1 2 Push fuel line fully onto nipple until it locks in place Figure 21 13 Page 21 18 1 3 Engage locking clip by pushing in until fully seated and completely prevents the l...

Page 347: ...ssary to build fuel pressure Any leaks found must be fixed DANGER Repair all fuel leaks before returning the vehicle to service 7 If no leaks are found place the neutral lockout switch in the OPERATE...

Page 348: ...ove and provide access to all of the fuel pump module hardware 5 8 Remove hardware 5 securing hold down ring 6 and ground wire 7 to fuel tank 9 Lift fuel pump module 1 out of fuel tank and drain into...

Page 349: ...e any drained gasoline from the area 9 Connect battery See Connecting the Battery Gasoline Vehicles on page 1 3 10 Place the Forward Reverse handle in the NEUTRAL position chock the wheels and the neu...

Page 350: ...el Pump Module GASOLINE VEHICLE FUEL SYSTEM 14 13 12 2 8 6 5 10 1 7 3 15 4 11 16 9 3125a Figure 21 15 Fuel System Precedent Exploded View Page 21 22 2019 Precedent Villager 2 Maintenance and Service M...

Page 351: ...ck the wheels and the neutral lockout switch in the MAINTENANCE position 2 Turn key switch to OFF position and remove key 3 Disconnect battery See Disconnecting the Battery Gasoline Vehicles on page 1...

Page 352: ...GE 1 Remove gas cap and fuel pump module from tank See Fuel Pump Module Removal on page 21 20 2 In a well ventilated area flush the fuel tank with water to remove any remaining fuel 3 In a well ventil...

Page 353: ...s plug 2 to fuel pump module 1 7 Clean spilled and remove any drained gasoline from the area 8 Connect battery See Connecting the Battery Gasoline Vehicles on page 1 3 9 Add fuel to tank 10 Place the...

Page 354: ...filter flex hoses are keyed to aid proper installation into fuel pump module NOTE The fuel filter is keyed to the fuel pump module to prevent incorrect assembly The inlet and outlet flex hoses are ke...

Page 355: ...1 securing three hoses 2 3 and 4 to canister 5 and disconnect hoses Figure 21 16 Page 21 27 4 Push or pull canister from mounting bracket 6 1 1 3 4 A 6 5 5 2 2 1 3 4 Detail A Side View 1 Clamp 2 Vent...

Page 356: ...NE VEHICLE FUEL SYSTEM 2 Attach hoses 2 3 and 4 to appropriate locations on carbon canister and secure with hose clamps 1 3 Install and or lower seat bottom Page 21 28 2019 Precedent Villager 2 Mainte...

Page 357: ...Figure 22 1 Page 22 2 2 Replace exhaust gasket 5 on the cylinder head exhaust port studs with a new gasket For exhaust gasket with raised port opening orient gasket 5 with raised section of gasket up...

Page 358: ...22 Muffler GASOLINE VEHICLE EXHAUST SYSTEM 3 4 2 1 6 5 5 7 8 9 3112a Figure 22 1 Exhaust System Page 22 2 2019 Precedent Villager 2 Maintenance and Service Manual...

Page 359: ...ce on the driven clutch This device overcomes the force of the centrifugal weights to close the driven clutch and open the drive clutch thus increasing axle torque with little or no change in engine R...

Page 360: ...Page 23 4 CC P N 1014496 CC P N 1014507 CC P N 101809101 CC P N 1014497 CC P N 105072501 CC P N 101808401 CC P N 1014508 WARNING 1 2 3 7 5 4 6 1 Drive Clutch Hub Puller 2 Driven Clutch Cam Puller 3 Dr...

Page 361: ...ft upward on the belt to force the sheaves of the driven clutch 1 apart then roll the belt off the driven clutch by rotating the clutch counterclockwise Figure 23 2 Page 23 3 See following CAUTION CAU...

Page 362: ...ard M10 12 Bushing Split Drive Clutch 4 Cap Plug 13 Sheave Moveable Drive 5 Drive Hub Assy Drive Clutch 14 Spacer Fixed Face Shaft 6 Ring 0 810 in 20 5 mm Internal Retaining 15 Spring Drive Clutch 7 D...

Page 363: ...ing Bolt 596 Figure 23 5 Drive Clutch Removal 3 Place chocks at the front wheels and lift the rear of the vehicle with a chain hoist or floor jack Place jack stands under the chassis to support the ve...

Page 364: ...and force the drive clutch 2 free of the crankshaft 7 Remove clutch puller tool from drive clutch CAUTION Do not hit or tap the clutch with a hammer Do not pry the clutch These actions will damage the...

Page 365: ...h Tighten bolts evenly making sure the face of the puller plate is parallel to the face of the clutch Figure 23 7 Page 23 7 2 4 Unscrew the puller center bolt out of the clutch to pull drive clutch hu...

Page 366: ...s 3 as shown Figure 23 9 Page 23 8 5 2 Pull the weight assemblies 3 with pins from slots 4 in the clutch See following NOTE NOTE Before removing note the orientation of the wave washer 1 and secondary...

Page 367: ...bore in the fixed sheave Figure 23 3 Page 23 4 See also Figure 23 11 Page 23 9 Discard the rings 605 Figure 23 11 Spiral Back up Rings INSPECTION OF DRIVE CLUTCH PARTS 1 Inspect the idler spacer 17 f...

Page 368: ...e retaining ring 6 Figure 23 3 Page 23 4 5 Install the primary weights 3 on the mounting pins 4 Figure 23 10 Page 23 9 6 Install a wave washer 1 on each mounting pin 4 Make sure that the concave side...

Page 369: ...and 16 Replace the three plastic plugs 4 into the holes Figure 23 3 Page 23 4 3054 Figure 23 13 Correct Orientation of Drive Button Take up Springs DRIVE CLUTCH INSTALLATION 1 Place the drive clutch a...

Page 370: ...23 Drive Clutch GASOLINE VEHICLE CLUTCHES 6 Drive the vehicle and check for proper operation Page 23 12 2019 Precedent Villager 2 Maintenance and Service Manual...

Page 371: ...Washer Driven Clutch 8 Button Drive 3 Ring Retaining 9 Sheave Movable Driven 4 Key Driven Clutch 10 Washer Acetal Driven Clutch 5 Cam Driven Clutch 11 Sheave Fixed Driven 6 Spring Driven Clutch 55 De...

Page 372: ...itions 1 Make match marks on the driven clutch fixed sheave and on the moveable sheave to maintain balance upon reassembly 2 Using external snap ring pliers remove the retaining ring 4 Figure 23 15 Pa...

Page 373: ...xed sheave if it is worn scratched or damaged DRIVEN CLUTCH ASSEMBLY 1 Place the three drive buttons 8 in position Apply one drop of Loctite 222 to each of the socket head cap screws 7 and then instal...

Page 374: ...rocess NOTE This process is for field assembly requirements where hydraulic and pneumatic press equipment is not available Use the cam installation tool for this process 5 2 1 With the clutch loosely...

Page 375: ...3 15 Page 23 15 NOTE The retaining ring 4 can be reused if the O D does not exceed 1 607 in 40 82 mm otherwise it must be replaced with a new ring DRIVEN CLUTCH INSTALLATION 1 To install the driven cl...

Page 376: ...Pagination Page 23 Driven Clutch GASOLINE VEHICLE CLUTCHES Page 23 18 2019 Precedent Villager 2 Maintenance and Service Manual...

Page 377: ...ing the vehicle to a complete stop before changing FORWARD or REVERSE direction NEUTRAL LOCKOUT For the convenience of the trained technician there is a neutral lockout switch located on the seat supp...

Page 378: ...ce under normal operating conditions The only service required is to maintain proper lubricant level See Lubrication on page 24 2 Under normal operating conditions adjustment to the system should not...

Page 379: ...p joint pliers 7 16 in socket 3 8 in drive Small flat blade screwdriver External snap ring pliers 0 047 in tip 1 2 in socket 3 8 in drive Medium flat blade screwdrivers 2 90 Internal snap ring pliers...

Page 380: ...he rear of vehicle 8 Remove the lug nuts and wheel 9 Slide brake drum off hub 10 Remove hub nut 4 and large flat washer 5 and pull hub 6 off axle shaft See following NOTE NOTE If the hub 6 does not sl...

Page 381: ...3 on hub nut 4 and install new cotter pin 2 If necessary tighten hub nut 4 further 177 ft lb 240 N m max until the locking cap 3 and new cotter pin 2 can be installed 11 Deform cotter pin 2 as shown F...

Page 382: ...can be done one side at a time without removing the transaxle 1 Clean debris from drain plug and area around it at the bottom of the transaxle Drain oil Install plug after draining 2 If removing entir...

Page 383: ...4 2 REAR WHEEL BEARING REMOVAL 1 Remove hub See Rear Hub Removal on page 24 4 2 Remove axle tube 2 from transaxle See Axle Tube and Axle Shaft Removal on page 24 6 3 Remove the snap ring 5 that is in...

Page 384: ...l 7 will sit Figure 24 5 Page 24 6 2 Using an appropriate sized seal driver drive in new oil seal 7 until 0 0393 in 1 mm below surface not fully seated 3 Clean end of axle shaft 3 and carefully instal...

Page 385: ...ug from limit switch on transaxle 8 Disconnect three wires of main wire harness from starter generator Figure 19 14 Page 19 13 9 Loosen jam nuts 1 securing shifter cable 2 to FNR accelerator cable mou...

Page 386: ...of Frame 17 Continue raising vehicle until chassis is higher than the top of the transaxle i e enough to allow powertrain to be rolled out from under vehicle Figure 24 10 Page 24 10 Position jack sta...

Page 387: ...om transaxle Dispose of gear oil properly 23 Remove driven clutch See Driven Clutch Removal Section 23 Page 23 14 24 Remove eight bolts 1 total that secure transaxle to powertrain Figure 24 13 Page 24...

Page 388: ...ction 1 6 Tighten lower nuts of shock absorbers until cushions expand to be the same diameter as the mounting washers 1 7 Tighten transaxle drain plug to 17 ft lb 23 5 N m 2 Fill transaxle with approp...

Page 389: ...24 14 Forward Reverse Handle SHIFTER CABLE See General Warnings on page 1 2 If the Forward Reverse shifter cable is damaged in any way it must be replaced SHIFTER CABLE REMOVAL NOTE Before removing c...

Page 390: ...e 2 in FNR accelerator cable bracket with a jam nut 1 on each side of bracket Figure 24 16 Page 24 14 Tighten jam nuts 1 to 22 ft lb 29 8 N m 3 Hook shifter cable end 4 into transaxle shift lever 5 an...

Page 391: ...Wire Color BLK Black BLU Blue LT BLU Light Blue BRN Brown GRAY Gray GRN Green ORG Orange PINK Pink PUR Purple RED Red TAN Tan WHT White YEL Yellow BLK_LT_BLUE Black with Light Blue Stripe BLK_ORG Blac...

Page 392: ...range with Black Stripe ORG_WHT Orange with White Stripe PUR_WHT Purple with White Stripe RED_GRN Red with Green Stripe RED_WHT Red with White Stripe RED_YEL Red with Yellow Stripe WHT_BLK White with...

Page 393: ...WIRING DIAGRAMS Electric Accessory Wiring Diagram 25 ELECTRIC ACCESSORY WIRING DIAGRAM WD1025104E5 L 2019 Precedent Villager 2 Maintenance and Service Manual Page 25 3...

Page 394: ...25 Electric Accessory Wiring Diagram WIRING DIAGRAMS WD1025104E5 R Figure 25 2 Electric Accessory Wiring Diagram Continued Page 25 4 2019 Precedent Villager 2 Maintenance and Service Manual...

Page 395: ...ELECTRIC MAIN HARNESS Wiring Diagrams Electric Main Harness 25...

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Page 397: ...ELECTRIC INSTRUMENT PANEL DASH HARNESS Wiring Diagrams Electric Instrument Panel Dash Harness 25...

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Page 399: ...GASOLINE MAIN HARNESS Wiring Diagrams Gasoline Main Harness 25...

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Page 401: ...GASOLINE INSTRUMENT PANEL DASH HARNESS Wiring Diagrams Gasoline Instrument Panel Dash Harness 18...

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Page 403: ...GASOLINE ENGINE HARNESS Wiring Diagrams Gasoline Engine Harness 25...

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Page 405: ...tallation 19 33 storage 19 34 testing 18 12 testing under load 18 12 18 31 voltage test 18 12 battery charger ERIC 15 1 AC service incoming 15 12 numbering vehicles and chargers 15 12 resetting power...

Page 406: ...rger receptacle bezel 4 9 installation 4 9 removal 4 9 charging system test procedures 15 16 choke button bezel installation 4 10 removal 4 10 cleaning brake assembly 6 4 seat 4 1 vehicle body 4 1 clu...

Page 407: ...itch installation 13 4 removal 13 3 testing 12 17 front body see body front 4 3 front bumper 4 5 fuel relieving pressure 21 4 fuel filter installation 21 26 removal 21 26 fuel gauge fuel gauge circuit...

Page 408: ...switch function engine testing 18 21 L leaf spring see suspension front and suspension rear 9 2 low oil warning light installation 19 27 removal 19 27 testing 18 30 lubrication front suspension 7 6 tr...

Page 409: ...ation 12 4 reverse buzzer installation 13 8 19 24 limit switch installation 19 25 removal 19 25 testing 18 30 removal 13 8 19 23 testing 12 29 18 30 RPM adjustment 21 9 21 13 S safety 1 1 safety commi...

Page 410: ...est procedures CDT connection 11 27 test procedures charger AC power and continuity test of AC circuit 15 17 battery condition using charger 15 16 battery voltage using multimeter 15 16 DC circuit con...

Page 411: ...ransaxle installation 24 12 lubrication 24 2 removal 24 9 service 24 2 transaxle type g assembly 17 9 axle bearing 17 4 axle shaft installation 17 4 removal 17 1 disassembly 17 7 inspection 17 7 insta...

Page 412: ...NOTES...

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