Ingersoll-Rand Club Car VILLAGER 6 ELECTRIC Operator'S Manual Download Page 9

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VILLAGER 6 ELECTRIC
Operators Manual
TPCC01BO00EN021 (Edition B)

Page vii

Maintenance Schedule ........................................................................................................................ 58

Overview......................................................................................................................................... 58
Service Schedule ............................................................................................................................ 58

Maintenance Tasks............................................................................................................................... 59

SECTION 9 – BATTERY MAINTENANCE ............................................................................................65

Battery Cleaning .................................................................................................................................. 66
Battery Charging ................................................................................................................................. 66

Charging With Onboard Charger ................................................................................................... 66

Battery Electrical Connection .............................................................................................................. 67

Disconnect ...................................................................................................................................... 67
Connect........................................................................................................................................... 68

SECTION 10 – TRANSPORT AND TOW ..............................................................................................73

SECTION 11 – EXTENDED STORAGE .................................................................................................77

Extended Storage Preparation ............................................................................................................ 78
Return To Service From Extended Storage ......................................................................................... 79

SECTION 12 – WARRANTIES ..............................................................................................................81

Limited Warranty ................................................................................................................................. 82

Summary of Contents for Club Car VILLAGER 6 ELECTRIC

Page 1: ...VILLAGER 6 ELECTRIC Operators Manual APPLICABLE TO VILLAGER 6 ELECTRIC VEHICLES WITH SERIAL PREFIX OF BO...

Page 3: ...the vehicle will make sure Club Car is able to communicate necessary information directly to owners Send your name address and serial number of the vehicle to Club Car LLC Attention Vehicle Registrat...

Page 4: ...ORMATION Send written correspondence to Club Car LLC Attention Marketing Services P O Box 204658 Augusta Georgia 30917 4658 United States Of America SATISFACTION AND FEEDBACK Let your voice be heard Y...

Page 5: ...RSONAL INJURY OR DEATH NOTICE MODIFICATIONS TO THE VEHICLE MUST NOT COMPROMISE COMPLIANCE WITH STATE OR FEDERAL REGULATIONS Modifications made to vehicles or installation of accessories that are not a...

Page 6: ...s vehicle complies when marked with an ICES decal with CAN ICES 2 NMB 2 as it was on the date the vehicle was shipped from the Club Car manufacturing facility EUROPEAN UNION VIBRATION AND NOISE PREN 1...

Page 7: ...l Safety Symbols 16 Lead Acid Battery Recycling 16 SECTION 2 INDICATORS GAUGES AND DISPLAYS 17 Indicator Gauge And Display Locations 18 Battery Condition Indicator 18 Charge Indicator Light 18 SECTION...

Page 8: ...SECTION 6 VEHICLE SPECIFICATIONS 37 Dimensions 38 Performance 38 Tires 38 Electric Motor 38 Batteries 38 Noise And Vibration 39 Transaxle 39 Vehicle Weights And Load Capacities 39 SECTION 7 VEHICLE O...

Page 9: ...ring System 68 Deionizer 70 Add Water To Batteries With Single Point Watering System 70 Watering Intervals 70 Water Quality 70 Overview 70 Preferred Sources 71 Alternate Sources 71 Water Impurity 71 S...

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Page 11: ...1 SAFETY INFORMATION VILLAGER 6 ELECTRIC Operators Manual TPCC01BO00EN021 Edition B Page 9 Safety Information Notices 1...

Page 12: ...hands hair and clothes away from rotating parts Hot surfaces can cause serious burns Allow to cool before servicing Signal words DANGER WARNING CAUTION and NOTICE and safety messages are in this manu...

Page 13: ...mittee is safe vehicle operation Safety committee objectives include Approve vehicle operation areas Identify all hazards Identify who is approved to operate the vehicle Keep the vehicles in a safe an...

Page 14: ...ERSONS PER BENCH SEAT ONLY RIDE ON THE BENCH SEAT DO NOT LET PEOPLE RIDE ON ANY PART OF THE VEHICLE THAT IS NOT EQUIPPED WITH A SEAT DO NOT LET A PASSENGER HOLD A CHILD IN HIS OR HER LAP WHILE THE VEH...

Page 15: ...l or drugs Never attempt jumps and avoid extreme braking in reverse 103961601 WARNING Before leaving vehicle Engage park brake to lock wheels Set the FNR control to NEUTRAL N Turn the key to OFF and r...

Page 16: ...tions Refer to the owner s manual 102967601 5 Component Cover Notice Decal 6 4 Gauge Wire Warning Decal VEHICLE SAFETY FEATURES BATTERY CHARGING INTERLOCK The battery charging interlock is a safety fe...

Page 17: ...pose buzzer will make an audible tone when the walk away braking safety device engages for more than two seconds BATTERY SAFETY INFORMATION DANGER BATTERY ACID CAN CAUSE SERIOUS BURNS PREVENT CONTACT...

Page 18: ...o open flames No sparks Keep away from children Explosive gas hazard LEAD ACID BATTERY RECYCLING WARNING LEAD ACID BATTERIES CONTAIN DANGEROUS MATERIALS THAT CAN CONTAMINATE THE WATER AND SOIL CAUSE E...

Page 19: ...2 INDICATORS GAUGES AND DISPLAYS VILLAGER 6 ELECTRIC Operators Manual TPCC01BO00EN021 Edition B Page 17 Indicators Gauges And Displays Battery Safety Information 2...

Page 20: ...l indication of the batteries state of charge SOC The battery condition indicator has a 10 bar LED display CHARGE INDICATOR LIGHT NOTICE WHEN THE CHARGE INDICATOR LIGHT IS ON CHARGE BATTERIES AS QUICK...

Page 21: ...TUS CONDITION OFF Battery SOC is more than 20 ON CONSTANT Battery SOC is less than 20 but more than 10 ON FLASH ON AND OFF Battery SOC is less than 10 ON FLASH ON AND OFF THREE TIMES The batteries cha...

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Page 23: ...3 VEHICLE CONTROLS VILLAGER 6 ELECTRIC Operators Manual TPCC01BO00EN021 Edition B Page 21 Vehicle Controls Charge Indicator Light 3...

Page 24: ...l 3 Park Brake 4 Key Switch 5 Headlight Switch Optional Equipment 6 Turn Signal Lever Optional Equipment 7 Hazard Lights Switch Optional Equipment 8 Horn Button Optional Equipment 9 Forward Neutral Re...

Page 25: ...e half normal operational speed POSITION FUNCTION NORMAL Closed Circuit Normal Operation TRIPPED Open Circuit 1 Stop the vehicle 2 Remove the bench seat to get access to the circuit breaker 3 Push to...

Page 26: ...ard light switch controls the operation of the hazard lights Move the turn signal switch up or down to turn off the hazard lights POSITION FUNCTION Out On In Off HEADLIGHT SWITCH The headlight switch...

Page 27: ...position when the vehicle is in use Electrical power from the batteries is available to power the motor and electrical systems PARK BRAKE WARNING FAILURE TO ENGAGE THE PARK BRAKE CAN CAUSE PROPERTY DA...

Page 28: ...for maintenance extended storage or when towed Wait 10 seconds before vehicle operation when the switch is set from TOW to RUN Do not quickly operate the switch from RUN to TOW and back to RUN Wait 1...

Page 29: ...4 VEHICLE FEATURES VILLAGER 6 ELECTRIC Operators Manual TPCC01BO00EN021 Edition B Page 27 Vehicle Features Turn Signal Lever 4...

Page 30: ...for two additional passengers and increased cargo space USB RECEPTACLE The 5 volt 2 1 amp USB receptacle supplies electricity to power and charge portable devices The USB receptacle is not for the mo...

Page 31: ...5 BATTERY CHARGER VILLAGER 6 ELECTRIC Operators Manual TPCC01BO00EN021 Edition B Page 29 Battery Charger USB Receptacle 5...

Page 32: ...NG STEPPED ON TRIPPED OVER OR SUBJECTED TO DAMAGE OR STRESS SPEAK WITH YOUR LOCAL DEALER OR DISTRIBUTOR FOR REPAIRS LIQUID ON THE BATTERY CHARGER CAN CAUSE PROPERTY DAMAGE ELECTRICAL SHOCK SERIOUS PER...

Page 33: ...mber 105161901 DIMENSION AND WEIGHT Dimension 11 in 28 cm length 9 7 in 24 6 cm width 4 3 in 11 cm height Weight 11 lb 4 9 kg OPERATIONAL TEMPERATURE Temperature Range 32 F to 86 F 0 C to 30 C AC INPU...

Page 34: ...G The battery charger has an International Protection Marking IP certification of IP66 The battery charger enclosure has an International Protection Marking IP certification of IP46 The battery charge...

Page 35: ...rate when the AC cord is connected EXTENDED STORAGE CHARGE The battery charger can stay connected to AC electrical power during off season or extended storage STATUS INDICATOR LIGHTS The status indica...

Page 36: ...ery cable from battery number 8 negative post 4 Plug the AC electrical cord into an approved power source Let the battery charger to do the start up self test 5 When the start up self test is done the...

Page 37: ...d to show a diagnostic code if a fault occurs To find the shown fault 1 Count the number of red flashes on the charger indicator lamp The charger will pause between fault code displays 2 Use the Fault...

Page 38: ...in a lower ambient temperature environment 4 Battery could not be trickle charged up to minimum voltage Inspect for worn or defective batteries Replace batteries as necessary 5 Charger shutdown becau...

Page 39: ...6 VEHICLE SPECIFICATIONS VILLAGER 6 ELECTRIC Operators Manual TPCC01BO00EN021 Edition B Page 37 Vehicle Specifications Troubleshooting 6...

Page 40: ...MANCE Forward Speed On Level Ground 14 to 16 mph 22 to 25 km h Turning Radius SAE J695 129 in 328 cm standard tires 152 6 in 387 6 cm premium tires Intersecting Aisle Clearance 89 8 in 228 cm standard...

Page 41: ...THE RATED CAPACITIES OF THE VEHICLE ARE EXCEEDED PROPERTY DAMAGE SERIOUS PERSONAL INJURY OR DEATH CAN OCCUR DO NOT EXCEED THE RATED CAPACITY OF THE VEHICLE RATED CAPACITY IS FOR LEVEL SURFACES ONLY T...

Page 42: ...upant Capacity A 1200 lb 544 3 kg Maximum Cargo Capacity B 300 lb 136 kg Maximum Trailer Tongue Weight C Not Applicable Maximum Gross Trailer Weight D Not Applicable Vehicle Rated Capacity 1500 lb 680...

Page 43: ...lied by the trailer tongue onto the trailer hitch Maximum Gross Trailer Weight The gross trailer weight is the trailer weight plus the weight of the load on the trailer Vehicle Rated Capacity The vehi...

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Page 45: ...7 VEHICLE OPERATION VILLAGER 6 ELECTRIC Operators Manual TPCC01BO00EN021 Edition B Page 43 Vehicle Operation Vehicle Weights And Load Capacities 7...

Page 46: ...SERIOUS PERSONAL INJURY OR DEATH IF PROBLEMS ARE FOUND DURING SCHEDULED INSPECTION OR SERVICE OPERATE THE VEHICLE ONLY WHEN REPAIRS ARE MADE MAKE SURE THAT ALL PASSENGERS CAN SECURE THEMSELVES IN THE...

Page 47: ...FROM THE DRIVERS SEAT OPERATE THE VEHICLE ONLY IN SPECIFIED AREAS ONLY AN AUTHORIZED LICENSED DRIVER CAN OPERATE THE VEHICLE ONLY OPERATE THE VEHICLE IN COMPLIANCE WITH LOCAL AND STATE LAWS USE CAUTI...

Page 48: ...y attached Tighten as necessary Examine the battery posts for corrosion If corrosion is found remove the corrosion Make sure that the batteries are fully charged Examine the battery acid level Add dei...

Page 49: ...al 3 Set the Forward Neutral Reverse control FNR to R Make sure that the multi purpose buzzer operates 4 Release the brake pedal 5 Slowly push the accelerator pedal Make sure the vehicle moves in reve...

Page 50: ...The Driving Instructions Indicators Gauges Displays Controls MOTOR START Before motor start Read and obey all safety decals and information located on the vehicle Understand how to operate the vehicle...

Page 51: ...ly Understand the function of all vehicle controls indicators displays and gauges Make sure that all passengers are seated with seat belts fastened if equipped and use the hand holds or handrails The...

Page 52: ...age the park brake 3 Slowly push the accelerator pedal SLOW OR STOP THE VEHICLE 1 Release the accelerator pedal 2 Push the brake pedal PARK THE VEHICLE 1 Stop the vehicle 2 Engage the park brake to pr...

Page 53: ...op a vehicle with a load on a slope If a vehicle with a load must stop on a slope prevent backwards movement or sudden starts or stops Do not go over the top of a hill at high speed Obstacles sharp dr...

Page 54: ...slope Prevent driving on slopes that exceed 20 grade Always examine the terrain carefully before driving on a slope Do not drive on a slope with slippery or loose surfaces Keep the heavy end of the ve...

Page 55: ...at night is not recommended When driving at night is unavoidable the vehicle must have Headlights Taillights Reflectors Precautions if driving at night is unavoidable Always have headlights on Always...

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Page 57: ...8 VEHICLE MAINTENANCE VILLAGER 6 ELECTRIC Operators Manual TPCC01BO00EN021 Edition B Page 55 Vehicle Maintenance Driving Conditions 8...

Page 58: ...OUS PERSONAL INJURY SET THE RUN TOW SWITCH TO TOW DISCONNECT THE BATTERIES WAIT 90 SECONDS FOR THE CONTROLLER DISCHARGE DO NOT WORK ON THE VEHICLE POWERTRAIN WHEN THE VEHICLE IS LOADED ELECTRICAL SHOR...

Page 59: ...OR STEAM CLEANER TO CLEAN THE VEHICLE Use only commercially available automotive cleaners with a sponge or soft cloth for normal cleaning A garden hose at normal residential water pressure is sufficie...

Page 60: ...SERVICE SCHEDULE Note The Maintenance Service Schedule must be done more frequently on vehicles that are constantly subjected to heavy use or severe operating conditions INTERVAL OR HOURS WHICHEVER C...

Page 61: ...front suspension lubricate the accelerator pedal 12 months 100 hours Have a trained technician examine the batteries front wheel bearings pedal components safety decals transaxle fluid MAINTENANCE TA...

Page 62: ...e onto the jack stands LIFT THE REAR OF THE VEHICLE WARNING LIFTING THE VEHICLE WITH CARGO CAN CAUSE PROPERTY DAMAGE SERIOUS PERSONAL INJURY OR DEATH REMOVE ALL CARGO FROM THE CARGO BED BEFORE THE VEH...

Page 63: ...ter of the lift point 2 Lift the rear of the vehicle 3 Put jack stands under the frame rails 4 Lower the vehicle onto the jack stands LOWER THE VEHICLE LOWER THE FRONT OF THE VEHICLE Before the front...

Page 64: ...the vehicle 1 Place the jack in the center of the lift point 2 Lift the vehicle off of the jack stands 3 Remove the jack stands 4 Lower the vehicle LOWER THE REAR OF THE VEHICLE Before the rear of the...

Page 65: ...e measurement Disable the vehicle To measure the tire pressure 1 Remove the valve stem cap 2 Use a pressure gauge to measure the tire pressure 3 Adjust to meet the recommended tire pressure Note Go to...

Page 66: ...cle to allow for installation of the wheel assembly 2 Align the wheel assembly onto the hub of the vehicle Note Make sure that the valve stem points to the outer side of the vehicle Note Make sure tha...

Page 67: ...316V 9 BATTERY MAINTENANCE VILLAGER 6 ELECTRIC Operators Manual TPCC01BO00EN021 Edition B Page 65 Battery Maintenance Maintenance Tasks 9...

Page 68: ...battery top and terminals Remove all corrosion 3 Use tap water to clean the solution from the batteries Correctly discard the waste water 4 If the battery cable has corrosion have a trained technician...

Page 69: ...rge in 10 seconds or less The charge indicator light will flash and the multi purpose buzzer will operate when the vehicle starts to charge 4 Before vehicle operation disconnect and retract the AC cor...

Page 70: ...OSE BATTERY WIRES CAN CAUSE A FIRE PROPERTY DAMAGE OR SERIOUS PERSONAL INJURY MAKE SURE THAT ALL BATTERY WIRES AND TERMINALS ARE CLEAN AND TIGHTENED CORRECTLY 4 Tighten the hardware to 110 lb in 12 4...

Page 71: ...ly charge the batteries 4 If the battery acid is below the top of the plates 4 A Add water until the battery acid is level with the top of the plates 4 B Install and lock the cap 4 C Fully charge the...

Page 72: ...stallation operation and maintenance manual hand pump manual and deionizer operator and maintenance manual WATERING INTERVALS The watering intervals are affected by Age of the batteries Application Ch...

Page 73: ...nes the quantity of solids or impurities which get caught and hence the purity quality of the filtered water Because of the variance in water quality consistency Club Car recommends the use of the dei...

Page 74: ...wering of on charge voltage Nitrates 10 0 Increased sulfation of negative plate Nitrites 5 0 Plate corrosion loss of capacity and decreased life Platinum None allowed Violent self discharge and lower...

Page 75: ...10 TRANSPORT AND TOW VILLAGER 6 ELECTRIC Operators Manual TPCC01BO00EN021 Edition B Page 73 Transport And Tow Water Quality 10...

Page 76: ...E TO BE TOWED 1 Turn the key to OFF 2 Remove the key Keep the key in a safe area 3 Set the Forward Neutral Reverse control FNR to N 4 Set the Run Tow switch to TOW TOWING A TRAILER OR VEHICLE CAUTION...

Page 77: ...anels seat bottoms and windshield 9 Examine the vehicle for loose parts Tighten as necessary 10 Secure the vehicle to the trailer VEHICLE TRANSPORT RECOVERY 1 Make sure that the trailer is correctly c...

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Page 79: ...11 EXTENDED STORAGE VILLAGER 6 ELECTRIC Operators Manual TPCC01BO00EN021 Edition B Page 77 Extended Storage Vehicle Transport Recovery 11...

Page 80: ...tended storage 1 Turn off all electronic accessories 2 Set the Forward Neutral Reverse control FNR to N 3 Turn the key to OFF 4 Remove the key Keep the key in a safe area 5 Put chocks against the whee...

Page 81: ...harger to the vehicle Keep battery chargers connected during storage The charger will automatically connect when necessary 14 B Examine the battery acid level and charger function monthly Note The cha...

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Page 83: ...12 WARRANTIES VILLAGER 6 ELECTRIC Operators Manual TPCC01BO00EN021 Edition B Page 81 Warranties Return To Service From Extended Storage 12...

Page 84: ...agency approved by Club Car For repairs made by qualified technicians other than Club Car s factory technicians or an Authorized Dealer or Distributor Club Car will provide only the replacement parts...

Page 85: ...illed water or a properly maintained Club Car approved battery water deionizer and filter system must be used to ensure water quality Abuse such as overcharging undercharging improper fluid levels loo...

Page 86: ...t at no cost to the purchaser Repair shall mean remedying a defect in the vehicle or component thereof at no cost to the purchaser during the applicable limited warranty period Club Car reserves the r...

Page 87: ...cle or defective component with evidence of proof of purchase date and number of amp hours if applicable to an authorized Club Car dealer For warranty related communication contact E mail cci_warranty...

Page 88: ...Publication Part Number TPCC01BO00EN021 Edition Code B Club Car LLC P O Box 204658 Augusta GA 30917 4658 USA Web Phone Fax www clubcar com 1 706 258 2225 1 800 ClubCar 1 706 863 5858...

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