Club Car Villager 6 Owner'S Manual Download

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Villager 6 and 8

Owner’s Manual

Electric and Gasoline

[Refer to back cover for applicable build code range]

Summary of Contents for Villager 6

Page 1: ...Villager 6 and 8 Owner s Manual Electric and Gasoline Refer to back cover for applicable build code range...

Page 2: ......

Page 3: ...tocopied reproduced or translated to another language without the written consent of Club Car LLC The information contained in this document is subject to change without notice Club Car reserves the r...

Page 4: ...rvice please contact your local authorized Club Car dealer or distributor who will be able to provide technical advice perform warranty work and sell parts and service manuals For the name and address...

Page 5: ...on a Trailer 28 Storage Electric Vehicles 29 Storage Gasoline Vehicles 31 Maintenance 32 Periodic Service Schedules 33 Periodic Lubrication Schedules 36 Batteries Electric Vehicle 38 Battery Charger I...

Page 6: ...6 AND 8 2886 7 6 5 1 3 2 4 1 101705701 Decal Falling Off Warning on rear facing seat hand rail and or on back side of forward facing seat backs 7 Battery Warning Light 2 102845101 Decal Tow Run Switc...

Page 7: ...701 Decal Falling Off Warning on rear facing seat hand rail and or on back side of forward facing seat backs 3 102967601 Decal 4 Gauge Wire Warning on frame in battery compartment 2 102518301 Decal Co...

Page 8: ...701 Decal Falling Off Warning on rear facing seat hand rail and or on back side of forward facing seat backs 3 102967601 Decal 4 Gauge Wire Warning on frame in battery compartment 2 102518301 Decal Co...

Page 9: ...rd facing seat backs 6 103783003 Decal Operating Instructions on steering wheel 2 101825102 Decal On Off Start Key Switch above key switch 3 103205401 Decal Rollover Warning on instrument panel 4 1032...

Page 10: ...2 1 3 1 101915201 Decal Frame Ground Governor Warning on vehicle frame near battery 4 105082301 Decal Gasoline Fuel Warning on fuel tank 2 101960501 Decal Rotating Parts Hot Manifold Warning on start...

Page 11: ...ature Identification GASOLINE VILLAGER 6 AND 8 CONTINUED 2920 1 1 101705701 Decal Falling Off Warning on rear facing seat hand rail and or on back side of forward facing seat backs Villager 6 and 8 Ow...

Page 12: ...ormation in this manual Understand and become familiar with the DANGER WARNING and CAUTION statements and procedures it contains along with the safety decals that are affixed to your vehicle Take time...

Page 13: ...afe practice that can result in minor personal injury CAUTION A CAUTION without the safety alert symbol indicates a potentially hazardous situation that can result in property damage GENERAL WARNINGS...

Page 14: ...e service or accessory installation Electric vehicles Ensure battery connections are clean and properly tightened See Battery Care on page 40 Place Tow Run switch in the TOW position before disconnect...

Page 15: ...irst 2 Tighten battery terminals to 80 in lb 9 N m 3 Coat terminals with Battery Terminal Protector Spray to minimize corrosion 4 Connect the spark plug wire s to the spark plug 1 2 Viewed from passen...

Page 16: ...12 4 N m 4 Coat terminals with Battery Terminal Protector Spray to minimize corrosion RECYCLING LEAD ACID BATTERIES WARNING Lead acid batteries contain lead Pb other metals acids and other compounds...

Page 17: ...to read and understand this manual and to pay special attention to the features specific to their vehicle s MODEL IDENTIFICATION The serial number of each vehicle is printed on a bar code decal mounte...

Page 18: ...vehicles equipped with a three position key switch are referred to as key start Electric vehicles The key switch has two positions OFF and ON Key start vehicles The key switch has three positions OFF...

Page 19: ...r pedal is pressed Club Car vehicles operate at reduced speed in reverse The reverse buzzer will sound as a warning when the Forward Reverse switch is in the REVERSE position Gasoline Vehicle The Forw...

Page 20: ...oard computer When the vehicle is in operation the warning light will illuminate and remain illuminated if Batteries voltage drops below 48 volts when there is no load on the batteries the vehicle is...

Page 21: ...be on When battery voltage drops below 75 of full discharge the last two indicator lights will flash alternately Continued use of vehicle after indicator lights begin flashing without recharging could...

Page 22: ...n some modes of operation In those modes the vehicle operates as follows Walk Away Braking This prevents the vehicle from rolling away uncontrolled should the driver park on a slope and leave the vehi...

Page 23: ...10 78 Figure 10 Brake Pedal 79 Figure 11 Park Brake PARK BRAKE PEDAL The park brake pedal is the small raised portion in the upper left corner of the brake pedal It has the word PARK molded into it a...

Page 24: ...te See following NOTE NOTE After placing the Tow Run switch in the TOW position allow 10 seconds to elapse before switching back to the RUN position After placing the Tow Run switch in RUN position al...

Page 25: ...s of rapid beeps will sound and vehicle speed will slow to approximately one half of its top programmed speed In the event of a tripped circuit breaker bring the vehicle to a complete stop remove seat...

Page 26: ...is in proper working condition and in conjunction with the Performance Inspection on page 25 and the Periodic Service Schedules on page 33 Any problems should be corrected by a Club Car distributor d...

Page 27: ...ould accelerate smoothly to full speed The vehicle will run at a reduced speed when in the REVERSE position When the pedal is released it should return to the original position and the motor should ro...

Page 28: ...slopes exceeding 20 incline Avoid stopping a loaded vehicle on a hill If a loaded vehicle must be stopped on a hill avoid sudden starts or rolling backwards and stopping suddenly Failure to heed this...

Page 29: ...the engine has started The engine will idle with the Forward Reverse handle in the NEUTRAL position 7 4 Keeping brake engaged place the Forward Reverse handle in desired position F Forward or R Revers...

Page 30: ...Run switch is in the RUN position with the Forward Reverse switch or key switch in any position the walk away braking function will prevent the vehicle from rolling at more than 1 to 3 mph 1 6 to 4 8...

Page 31: ...atures To avoid exposing electrical components to moisture and subsequent damage do not use any type of pressure washing or steam cleaning equipment to wash the vehicle PREPARING THE ELECTRIC VEHICLE...

Page 32: ...nnect batteries for storage go to step 13 12 To keep batteries fully charged during storage 12 1 Plug the battery charger into the car Leave battery chargers plugged in during storage The onboard comp...

Page 33: ...propriate instructions must be used when performing maintenance service or accessory installation Turn the key switch to the OFF position remove the key and leave the Forward Reverse handle in the NEU...

Page 34: ...and the neutral lockout switch in the MAINTENANCE position Crank the engine until the engine starts Turn the engine off and return the neutral lockout switch to the OPERATE position See following NOT...

Page 35: ...ects to contact frame when disconnecting batteries or other electrical wiring Never allow a positive wire to touch the vehicle frame engine or other metal component PERIODIC SERVICE SCHEDULES WARNING...

Page 36: ...ke cables for damage replace if necessary Brake system Check brake cable equalizer adjustment adjust if necessary Electrical wiring and connections Check for tightness and damage Forward Reverse switc...

Page 37: ...camber Check and adjust if necessary Refer to the appropriate maintenance and service manual Electrical wiring and connections Check for tightness and damage Check brake shoes replace if necessary or...

Page 38: ...s Dry Moly Lube CC PN 1012151 Semiannually by owner or trained technician or every 50 hours of operation whichever comes first Front suspension Chassis Lube EP NLGI Grade 2 Transaxle Check fill to plu...

Page 39: ...of operation whichever comes first Brake slides Dry Moly Lube CC P N 1012151 Transaxle Check fill to plug level 67 6 fl oz 2 L SAE 80W 90 API Class GL 5 Annually by trained technician only or every 1...

Page 40: ...cle or dispose of discarded batteries in accordance with local state and federal regulations Club Car electric vehicles use deep cycle batteries Automotive batteries should never be used in electric v...

Page 41: ...ng is an alternate method of battery watering its use should be limited due to the levels of dissolved minerals and chemicals that can degrade battery performance and life If unfiltered tap water is u...

Page 42: ...em with Battery Terminal Protector Spray See following NOTE NOTE Dispose of waste water properly 2 The electrolyte level in the batteries should be checked weekly Figure 16 Add water only after chargi...

Page 43: ...ries are being charged An accumulation of hydrogen gas can result in an explosion WARNING Only trained technicians should repair or service the charger Contact a Club Car distributor dealer Each charg...

Page 44: ...ins or contacts are bent or corroded The plug receptacle or cords are cut worn have any exposed wires or are damaged in any way Using a charger with any of the above symptoms can result in fire proper...

Page 45: ...n accordance with the National Electric Code and all local codes and ordinances The charger will turn on two to ten seconds later Club Car battery chargers interact with the vehicle onboard computer T...

Page 46: ...spray lubricant The plug should then be inserted and removed several times to ensure ease of insertion ease of removal and good electrical contact See following NOTE NOTE If the warning tag has been d...

Page 47: ...fully when working with batteries Charge battery in a well ventilated area only Battery Poison Contains acid Causes severe burns Avoid contact with skin eyes or clothing Antidotes External Flush with...

Page 48: ...d replace or clean them as necessary Failure to do so can cause them to overheat during operation and can result in a fire property damage or personal injury Be sure battery clamp is properly tightene...

Page 49: ...deral regulations 3 2 1 1 Full level 2 Safe level 3 Low level 2662 Figure 22 Engine Oil Level Check ENGINE OIL CHANGE Engine oil should be changed after the first 100 hours of operation After that it...

Page 50: ...ndling 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 sock...

Page 51: ...fuel tank ground wire on the tank is properly connected before fueling the vehicle To avoid electric arc caused by static electricity the fuel storage pumping device must be grounded If the pump is no...

Page 52: ...washing or steam cleaning Such a process especially if the vehicle has an ArmorFlex rear body that has been removed will expose electrical components to moisture Moisture entering electrical component...

Page 53: ...ying objects CAUTION Combined use of electric powered accessories for an extended period of time could discharge the battery even with the engine running Be aware of charging system capacity rating an...

Page 54: ...pinion Suspension Front and rear multi leaf springs with dual hydraulic shocks Brakes Mechanical brake cable system to manually adjusted drum brakes on all four wheels Park brake is automatically rele...

Page 55: ...il 6 129 in 328 cm Vil 8 191 in 485 cm Intersecting aisle clearance Vil 6 89 8 in 228 cm Vil 8 108 in 274 cm Floorboard height 11 8 in 30 cm Seat height 30 in 76 cm Vehicle rated capacity level surfac...

Page 56: ...cle 17 17 17 DC voltage VDC end of charge cycle 60 60 60 DC current amps end of charge cycle 4 7 4 7 4 7 DIMENSIONS WEIGHT Case overall length 10 25 in 26 cm 10 25 in 26 cm 10 25 in 26 cm Case overall...

Page 57: ...s 13 0 DC OUTPUT DC voltage VDC start of charge cycle 48 DC current amps start of charge cycle 17 DC voltage VDC end of charge cycle 60 DC current amps end of charge cycle 4 7 DIMENSIONS WEIGHT Case O...

Page 58: ...at 200 VAC 50 Hz 7 6 7 6 Max AC current amps at 200 VAC 60 Hz 7 4 7 4 Max AC current amps at 220 VAC 50 Hz 7 0 7 0 Max AC current amps at 220 VAC 60 Hz 6 7 6 7 Max AC current amps at 240 VAC 50 Hz 6 4...

Page 59: ...VAC 60 Hz 14 6 Max AC current amps at 200 VAC 50 Hz 7 6 Max AC current amps at 200 VAC 60 Hz 7 4 Max AC current amps at 220 VAC 50 Hz 7 0 Max AC current amps at 220 VAC 60 Hz 6 7 Max AC current amps...

Page 60: ...reverse with optional limited slip differential Electrical system 12 volt 500 cca at 0 F 17 8 C 650 cca at 32 F 0 C 105 minute reserve capacity Torque converter Automatic variable speed dry type STEE...

Page 61: ...earance Vil 6 89 8 in 228 cm Vil 8 108 in 274 cm Floorboard height 11 8 in 30 cm Seat height 30 in 76 cm Vehicle rated capacity level surface only 1500 lb 680 kg Standard seating capacity Vil 6 6 Vil...

Page 62: ...anopy systems seats pedal group assembly body cab assembly and doors and driving range protective enclosure portable refreshment center and all original equipment options and accessories supplied by C...

Page 63: ...IT HAS BEEN ALTERED IN ANY WAY INCLUDING BUT NOT LIMITED TO MODIFICATION OF THE SPEED GOVERNOR BRAKING SYSTEM STEERING TRANSAXLE OR OTHER OPERATING SYSTEMS OF THE CAR TO CAUSE IT TO PERFORM OUTSIDE C...

Page 64: ...S COMPONENT DEFECT WARRANTY EMISSIONS COMPONENT DEFECT WARRANTY COVERAGE This emission warranty is applicable in all States except the State of California Club Car LLC CLUB CAR warrant s to the initia...

Page 65: ...ments within a reasonable amount of time and furnish you with a copy of the repair order All parts and accessories replaced under this warranty become the property of CLUB CAR For owners located more...

Page 66: ...IN PERFORMANCE AND DURABILITY TO AUTHORIZED PARTS MAY IMPAIR THE EFFECTIVENESS OF THE EMISSION CONTROL SYSTEM AND MAY HAVE A BEARING ON THE OUTCOME OF A WARRANTY CLAIM If other than the parts authoriz...

Page 67: ...CAR according to subsection 4 below Any such part repaired or replaced under warranty will be warranted for the remainder of the original warranty period 2 Any warranted part that is scheduled only f...

Page 68: ...park plug cap spark plug Positive Crankcase Ventilation PCV System PCV valve oil filler cap Evaporative System Fuel Tank Fuel Cap Fuel Lines Fuel Line Fittings Clamps Pressure Relief Valves Purge Valv...

Page 69: ...y Standards used for verification Standards fur Uberprufung Normes Utilisees pour Verification Normas Usado por Comprobacion Waarden Aangewend voor Verificatie Modelos Utilizado para Verifcacao Standa...

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Page 72: ...Publication Part Number 105062706 Edition Code 1113A00000 This manual is valid for vehicles with build codes between 56658 and the one indicated at the top of this page 105062706...

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Club Car Villager 6, Owner'S Manual

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