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Villager LSV OM-103700406 1009D1010C

1. 1880 Figure 13 Lubrication Points Villager LSV Owner s Manual Page 33 Batteries BATTERIES See General Warnings on page 11 A DANGER e Battery Explosive gases Do not smoke Keep sparks and flames away from the vehicle and service area Ventilate when charging or operating vehicle in an enclosed area Wear a full face shield and rubber gloves when working on or near batteries e Charge batteries in a well ventilated area only Batteries emit hydrogen while being charged Hydrogen is an explosive gas and must never exceed a level of 2 of the air e Battery Poison Contains acid Causes severe burns Avoid contact with skin eyes or clothing Antidotes External Flush with water Call a physician immediately Internal Drink large quantities of milk or water followed with milk of magnesia or vegetable oil Call a physician immediately Eyes Flush with water for 15 minutes Call a physician immediately A WARNING e 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 batteries e Use insulated tools when working near batteries or electrical connections Use extreme caution to avoid shorting
2. Do not operate this vehicle in a manner that impedes traffic Only operate vehicle in compliance with local and state laws Never operate under the influence of alcohol or drugs Drive slowly in tums and straight up and down slopes Operate from driver side only Keep entire body inside vehicle and hold on to seat handle while moving Two 2 persons per bench seat maximum Children requiring a child safety seat must not ride on the vehicle Do not leave children unattended on vehicle wnh This vehicle does not conform to ANSI Z130 1 IMPORTANT Standard for Golf Cars Safety and Performance Requirements because it is capable of speeds in NOTICE excess of 15 miles per hour Exercise caution CCI 102555901 A 1 VEHICLE EMISSION CONTROL INFORMATION This vehicle is covered by one or more of the following U S This vehicle is certified to patents as applicable D431018 D436557 D442402 D444328 CLUB CAR INC operate on stored electric energy D449806 DES 271008 DES 292899 DES 354264 DES 394617 avert Tori i g DES 409296 4343503 4539162 4637270 4821827 4826467 be cogio to California regulations applicable to 5042519 5083736 5403240 5543243 5565760 5788255 5857692 YYYY Model Year new ZEV passenger cars 5915495 6087805 6114833 6170787 6186584 6209796 6213145 Test Group YIRC00000002 103756501 Decal Collision Rollover or Falling Off Warning E Decal Operating Instructions on wiper
3. CEs Villager LSV Owner s Manual Zero Emission Electric Low Speed Vehicle Refer to back cover for applicable build code range LY Ingersoll Rand Industrial Technologies NOTICE This manual is valid for vehicles manufactured in the build code range provided on the back cover of this manual If the vehicle build code is different from that shown on the back cover of this manual please contact your nearest dealer or go to www clubcar com to retrieve the proper owner s manual for the vehicle See also Model Identification in this manual Warranty information appears at the end of this manual No other warranties express or implied are contained herein If you are the original purchaser of this vehicle please contact Club Car LLC or your authorized dealer if you did not receive a copy of the completed vehicle warranty registration form Club Car is not liable for errors in this manual or for incidental or consequential damages that result from the use of the material in this manual This manual contains proprietary information that is protected by copyright All rights are reserved No part of this manual may be photocopied 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 right to make design changes to vehicles without obligation to make these changes on units previously sold
4. The vehicle referenced herein has been designed and manufactured to comply with the United States National Highway Transportation and Safety Administration s Low Speed Vehicle rules and regulations in effect at the time of manufacture The operation of this vehicle is also subject to all applicable state and local laws the effect of which may be to further limit or prohibit the lawful operation of this vehicle in certain environments This vehicle conforms to FMVSS 500 for low speed vehicles as it existed on the date the vehicle was shipped from Club Car s manufacturing facility If in English this manual is the Original Instructions provided by the manufacturer If in any language other than English this manual is a translation of the Original Instructions Club Car i P O Box 204658 Augusta Georgia 30917 4658 USA Telephone 706 863 3000 Service Parts Fax 706 855 7413 www clubcar com Copyright 2010 Club Car LLC Club Car Tranquility and ArmorFlex are registered trademarks of Club Car LLC This manual effective July 1 2010 Villager LSV Owner s Manual Page 1 FOREWORD Thank you for choosing Club Car the name most widely recognized as the industry leader in vehicle efficiency and long lasting value You have chosen the finest utility vehicle on the market Please protect your investment and ensure that your Club Car vehicle s provides years of reliable superior performance by reading and following the maintenan
5. e Batteries in a low state of charge will freeze at low temperatures e To avoid exposing electrical components to moisture and subsequent damage do not use any type or pressure washing or steam cleaning equipment to wash the vehicle PREPARING THE VEHICLE FOR EXTENDED STORAGE 1 Unload the vehicle so that tires are supporting only the weight of the vehicle 2 Fully charge batteries See Charging Batteries on page 39 3 Batteries should be clean and free of corrosion Wash tops and terminals of batteries with a solution of baking soda and water 1 cup 237 mL baking soda per 1 gallon 3 8 L of water Rinse solution off batteries Do not Villager LSV Owner s Manual Page 29 Maintenance OMWN Oa A allow this solution to enter the batteries Be sure terminals are tight Let the terminals dry and then coat them with Battery Terminal Protector Spray CC P N 1014305 Store vehicle in a cool dry place This will minimize battery self discharge Adjust tires to recommended tire pressure See Vehicle Specifications on page 44 Perform semiannual periodic lubrication See Periodic Lubrication Schedule on page 33 Thoroughly clean front body rear body seats cargo bed battery compartment and underside of vehicle Do not engage the park brake Properly chock the wheels to prevent the vehicle from rolling Keep batteries fully charged during storage 9 1 Leave battery chargers plugged in during storage The onboard computer OBC w
6. 3 onto the deionizer water hose check the screen filter 4 inside the end of the assembly to make sure it is clean Figure 15 3 Connect the purger 5 to the female coupler 8 on the end of the hose end assembly Figure 16 Page 40 Villager LSV Owner s Manual Single Point Watering System SPWS 68 69 Figure 15 Connecting Hose with Filter to Water Source Figure 16 Checking the Water Flow Rate 4 Completely open the water faucet until the water flows out of the regulator 3 and note the movement of the red flow indicator balls 6 See following NOTE NOTE The water flow rate must be at least two gallons per minute for the SPWS to function properly This step also eliminates any trapped air from the water hose 5 Check the water quality light on the deionizer to make sure the light is green in color indicating acceptable water quality If the light indicates unacceptable water quality the cartridge must be replaced 6 After ensuring adequate water flow rate press the grey button 7 on the end of the female coupler 8 to disconnect the purger from the regulator Refilling the Batteries 1 Locate the battery fill coupling 9 on the driver side of the battery compartment remove the dust cover 10 from the male connector Figure 17 and connect the regulator 3 Figure 18 The water flow will begin immediately Villager LSV Owner s Manual Page 41 Single Point Watering Sy
7. Augusta Georgia 30917 4658 U S A 706 863 3000 CLUB CARO LIMITED FOUR YEAR WARRANTY FOR ONBOARD COMPUTERS AND SOLID STATE SPEED CONTROLLERS FOR LOW SPEED VEHICLES CLUB CAR LLC CLUB CAR hereby warrants to the original retail purchaser that the new Onboard Computer and the Solid State Speed Controller hereinafter called Computer and Controller respectively installed in its new Low Speed Vehicles equipped with the PowerDrive system purchased from CLUB CAR or an authorized distributor or dealer will be free from defects in material and workmanship for a period of four years from the date of purchase subject to the terms and conditions contained herein This limited warranty only covers defects in material and workmanship for a period of four years or 16 000 energy units as recorded by the Computer from date of purchase The terms of this four year limited warranty shall be as follows Vehicles used for commercial purposes free replacement with respect to parts and labor within four years or 16 000 energy units whichever first occurs from date of purchase The Computer or Controller should be returned to an authorized CLUB CAR distributor or dealer with evidence of proof of purchase date and the EU s used as shown by the computer CLUB CAR reserves the right to test any Computer returned for warranty and to verify EU s used by accessing information contained in the Computer LIMITED WARRANTY EXCLUSIONS THE PR
8. DAMAGES IN NO EVENT SHALL CLUB CAR BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING BUT NOT LIMITED TO LOSS RELATED TO PROPERTY OTHER THAN THE VEHICLE LOSS OF USE LOSS OF TIME INCONVENIENCE OR ANY OTHER ECONOMIC LOSS Some states allow neither limitation on the duration of an implied warranty nor exclusions or limitation of incidental or consequential damages Therefore the above limitations or exclusions may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state INFORMATION For further information contact WARRANTY SERVICES CLUB CAR LLC P O Box 204658 Augusta Georgia 30917 4658 U S A 706 863 3000 WARNING Any modification or alteration of any vehicle beyond factory specifications including those that affect the weight distribution stability or speed of the vehicle can cause serious personal injury or death Villager LSV Owner s Manual Page 47 Warranties CLUB CARO LIMITED FOUR YEAR WARRANTY FOR LOW SPEED VEHICLE LSV BATTERIES CLUB CAR LLC CLUB CAR hereby warrants to the original retail purchaser that the new batteries installed in its new electric utility vehicle purchased from CLUB CAR or an authorized distributor or dealer will be free from defects in material and workmanship This limited warranty only covers defects in material and workmanship for a period of four years or prescribed energy units from
9. P N 1014305 Dry Moly Lube CC P N 1012151 Page 2 Villager LSV Owner s Manual TABLE OF CONTENTS Practico OY ii a ii AA A aa ede ede A 4 Proposition 65 State of Calif rnia orena a iaai naa iiaa e ar on aae a aa nn n nen nn nn a a A aa Aa Ai 5 Reporting satety Detects ae EIEEE E a AR A EEE Er 5 Safety Decal and Feature Identification ce rE reer nner eee ane EAEAN AAAA AA aAa AA NASAAN Aaaa 6 Saby DRE aa a E EO EON 11 General Warnings massera aetra E R AEIR ln a hls dl aa 11 General INTO MAN dd a a ete 15 Model dC A dad 16 Controls and Indicators oocciicicr aaa Lia aida 16 OBS o es ee le e a a ll a 22 Transporting Children coo Atr s 25 Pre Operation and Daily Safety CheckliSt onmococionnnnnnccncnnnrccrnnnn rr 25 Driving INSTUCIONS dd r 26 Transporting On a Trae aida 28 Storage rnet cabin caddabiod Mates ten cichendebalchecdenotendedscnleneedebneanecte bed iecedied beets baddeetbedidateeeciacandacaieeatdeesiens aeons 29 Mantenan vic A Aida 30 Peri IC Service SCA dd 31 Periodic Lubrication Schedule ccoo nic dida 33 Bat iii a DAD NN dd oa ad sad 34 Batten Char A A atte 38 Single Point Watering System SPWS Jeer n apeiirdrr iiras iaia arpia a r aa Ipa a paa a aa ai ai aA A raS 40 Cleaning the Vehicle eurn a EA a a e a a a a a O T 43 ACCESS S neis iien Terei A EEE a a A er rA Eea KENEEN A A A cence 43 Subsequent Owner Registration 200 0 cite rere nro naa ANAA iaaa EE Aa aa A adaa 43 Vehicle Specifications o
10. grades the vehicle may slightly exceed its maximum programmed speed requiring the use of the brake pedal Also travel downhill with the accelerator pedal partially pressed Motor braking should limit speed to less than top speed and maintain speeds proportional to the accelerator pedal position On a level surface accelerate the vehicle to full speed and then release the accelerator pedal Motor braking should smoothly slow the vehicle to a complete stop DRIVING INSTRUCTIONS A WARNING The driver must possess a valid unrestricted driver s license issued by the State in which the vehicle will be operated e Before allowing anyone to drive the vehicle make sure the driver is familiar with all controls and operating procedures No more than four people should be on the vehicle at one time e The driver and passengers must be restrained at all times with seat belts to help prevent injury in the event of sudden braking or collision e Do not allow people to ride in any part of the vehicle that is not equipped with a seat and a seat belt Do not allow a third person to sit in the middle of the seat or allow a passenger to hold a child in his or her lap while the vehicle is moving e The vehicle is not specially equipped for handicapped persons WARNING CONTINUED ON NEXT PAGE Page 26 Villager LSV Owner s Manual Driving Instructions A WARNING Be sure all persons can properly operate the vehicle prior to allowing
11. motor 2 101825101 Decal On Off 11 103757901 cover Decal Do Not Ride in Bed Only with Cargo Bed 3 101972001 12 Tail Brake Turn Light Option 102322704 Decal VIN VILL 2 LSV EA Slow Moving Vehicle Warning Triangle 5 102555901 Decal Private Speed Notice on vehicles with the 14 License Plate Holder golf bag rack attachment 6 103501401 Decal 25 MPH Vehicle N J Only pas 3rd Brake Light 103515002 Decal Vehicle Emissions Control Information fre Reverse Light a 103537001 nee Vehicle Disclosure under canopy on driver 103593401 Decal Environmental Performance 1012647 1012647 Decal Patent Villager LSV Owner s Manual Page 7 Safety Decal and Feature Identification VILLAGER 2 LSV NOTICE Do not operate vehicle without this cover properly installed Do not direct water stream in this area will cause damage to components See vehicle maintenance and service manual before servicing MFD BY CLUB CAR INC DATE x0000 2009 GVWR 1930 LBS 875 KG GAWR FRONT 445 LBS 201 KG REAR 1485 LBS 674 KG RIMS 8X7 TIRES 215 60 R8 35 PSI TOW RUN THIS VEHICLE CONFORMS TO ALL APPLICABLE US FEDERAL MOTOR VEHICLE SAFETY STANDARDS IN EFFECT ON THE DATE OF Place Tow Run switch in TOW position before FAILURE TO HEED THIS rn Disconnecting or connecting batteries WARNING COULD RESULT caisson RAA ETS IN A BATTERY EXPLOSION A Estonio storage OR SEVERE PERSONAL ervicing INJUR
12. pedals 5 Make sure wheels are turned in desired direction and that nothing is obstructing vehicle s path 6 Press and hold the brake pedal Villager LSV Owner s Manual Page 27 Transporting on a Trailer 7 Start the vehicle 7 1 Turn the key to the ON position 7 2 Release the park brake 7 3 Select direction by placing the Forward Reverse switch in the desired position F forward or R reverse A buzzer will sound as a warning when the Forward Reverse switch is in the REVERSE position 7 4 Release the brake pedal completely and then slowly press the accelerator pedal As the accelerator pedal is pressed speed will increase until full speed is reached See following WARNING 4 WARNING e Operator must control vehicle speed when going downhill e Motor braking may be used to help control speed when going downhill however steep terrain or other conditions may require that pedal braking be used in conjunction with motor braking STOPPING THE VEHICLE 4 WARNING e Driving through water may affect the brakes After driving through water check effectiveness of the brakes by gently pressing the brake pedal If the vehicle does not slow down at the normal rate continue to press the brake pedal until the brakes dry out and normal performance returns A CAUTION When stopped on a hill use the brake pedal to hold your position Do not use the accelerator pedal to hold position To stop vehicle release the
13. periodic service 4 WARNING e If any problems are found during scheduled inspection or service do not operate the vehicle until repairs are made Failure to make necessary repairs could result in fire property damage severe personal injury or death Hot Do not attempt to service motor Attempting to do so could cause severe burns e Do not work on vehicle powertrain or under the cargo bed when it is loaded Do not wear loose clothing or jewelry such as rings watches chains etc when servicing the vehicle e Turn the key switch to OFF remove the key place the Forward Reverse switch in the NEUTRAL position and chock tires prior to servicing PERIODIC SERVICE SCHEDULE See General Warnings on page 11 4 WARNING e Service repairs and adjustments must be made per instructions in the maintenance and service manual If any problems are found during scheduled inspection or service do not operate the vehicle until repairs are made Failure to make necessary repairs could result in fire property damage severe personal injury or death NOTE If the vehicle is constantly hauling heavy loads or hauling a trailer these preventive maintenance procedures should be performed more often than recommended in the Periodic Service Schedule Both the Periodic Service Schedule and the Periodic Lubrication Schedule must be followed to keep vehicle in optimum operating condition Villager LSV Owner s Manual Page 31 Perio
14. restored LED Light In addition to the warning light there is an infrared LED in the dash light assembly which transmits an infrared signal from the onboard computer OBC This signal is received by the optional Communication Display Module which provides information on the condition of the vehicle and batteries BATTERY CONDITION INDICATOR OPTION The battery condition indicator features a 10 bar LED display that when the vehicle is in operation displays the level of battery capacity measuring battery voltage over a period of time When batteries are fully charged all indicator lights will 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 result in decreased vehicle performance See following NOTE NOTE If battery condition indicator moves rapidly approximately 45 minutes from full charge display to empty there may be a problem with the wiring or with a battery cell If indicator display does not reset back to full after recharging there may be a problem with the battery charger or with one of the batteries In either case the vehicle should be checked by a Club Car dealer or a trained technician Page 18 Villager LSV Owner s Manual Controls and Indicators ACCELERATOR PEDAL The accelerator pedal is the pedal on the right with the word GO molded into it Figure 6 The o
15. them to drive the vehicle Be sure all passengers are capable of securing themselves in a vehicle before allowing them to ride in one e Stop the vehicle before shifting the Forward Reverse switch Failure to do so may result in injury to inattentive passengers and or damage to the vehicle e Do not leave children unattended on vehicle e To help avoid being struck do not stand in front of or behind the vehicle e Operate the vehicle from the driver seat only To help prevent falls from the vehicle remain seated in a moving vehicle with seat belt fastened Driver should keep both hands on the steering wheel when the vehicle is in motion e To help prevent the possibility of serious injury keep entire body inside the vehicle e To help prevent overturning the vehicle drive slowly in turns To help prevent overturning the vehicle drive slowly straight up and down slopes Avoid driving the vehicle on slopes exceeding 20 grade e 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 warning could result in overturning the vehicle e To help avoid possible injury to inattentive passengers and or damage to the vehicle avoid sudden starts sudden stops and abrupt turns e To help avoid the possibility of losing control of or overturning the vehicle reduce speed for adverse driving conditions such as wet
16. to a vehicle throughout the storage period At one hour and at two hours into the charge cycle the charger will shut off in order to run a self diagnostic program ammeter will drop to zero Charging will resume in a few moments ammeter returns to previous rate of charge Each electric vehicle is supplied with a fully automatic onboard charger as standard equipment The AC cord from the charger should be connected to a source capable of supplying 15 amperes minimum per charger To reduce the risk of electric shock the battery charger must be grounded The charger is equipped with an AC electric cord having an equipment grounding conductor and a grounding 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 See the owner s manual supplied with the charger for specific operating instructions before using the charger The use of an extension cord with the charger should be avoided If an extension cord must be used use a three conductor no 12 AWG American Wire Gauge or no 14 SWG British Standard Wire Gauge heavy duty cord with ground properly wired and in good electrical condition Keep it as short as possible no more than 12 feet 3 7 m Place all cords so they will not be stepped on tripped over or otherwise subject to damage or stress Ensure that the charger ventilation slots are unobstructe
17. ECTION After you have familiarized yourself with the vehicle controls and have read and understood the driving instructions take the vehicle for a test drive Use the following checklist in conjunction with the Daily Pre Operation and Safety Checklist as a guide to inspect the vehicle and check daily for proper operation Any problems should be corrected by a Club Car distributor dealer or a trained technician Forward Reverse control Check for proper operation See Controls and Indicators on page 16 Brakes Be sure the brakes function properly When brake pedal is fully pressed under moderate pressure it should not go more than halfway to the floor and vehicle should come to a smooth straight stop If the brake Villager LSV Owner s Manual Page 25 Driving Instructions pedal goes more than halfway to the floor or if the vehicle swerves or fails to stop have the brake system checked and adjusted as required Brake adjustment must be maintained so that the brake pedal cannot be pressed to the floor under any circumstance e Park brake When latched the park brake should lock the wheels and hold the vehicle stationary on an incline of 20 or less It should release when pressure is applied to the brake pedal e Reverse buzzer The reverse buzzer should sound as a warning when the Forward Reverse switch is in the REVERSE position e Steering The vehicle should be easy to steer and should not have any play in the steering
18. HE SOLE REMEDY OF THE PURCHASER CLUB CAR MAKES NO OTHER REPRESENTATION OR WARRANTY OF ANY KIND AND NO REPRESENTATIVE EMPLOYEE DISTRIBUTOR OR DEALER OF CLUB CAR HAS THE AUTHORITY TO MAKE OR IMPLY ANY REPRESENTATION PROMISE OR AGREEMENT WHICH IN ANY WAY VARIES THE TERMS OF THIS WARRANTY This battery is intended to be used by persons with training and experience with batteries and only in CLUB CAR electric vehicles Any other use renders the Limited Warranties expressed herein and all implied warranties null and void and same are hereby excluded ALSO EXCLUDED FROM THIS LIMITED WARRANTY ARE ANY AND ALL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING BUT NOT LIMITED TO LOSS OF USE OR REVENUE LOSS OF TIME INCONVENIENCE OR ANY OTHER ECONOMIC LOSS Po NS Page 48 Villager LSV Owner s Manual Warranties Damage not resulting from a defect in material or workmanship or that occurs due to abuse or neglect including failure to provide reasonable and necessary maintenance accident or alteration is excluded from this limited warranty Some states allow neither limitation on the duration of an implied warranty nor exclusions or limitations of incidental or consequential damages Therefore the above limitations or exclusions may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from states to states For further information contact WARRANTY SERVICES CLUB CAR LLC P O Box 204658
19. OVISIONS OF THIS LIMITED WARRANTY SHALL NOT APPLY TO FAILURE DUE TO 1 Abuse or neglect such as improper battery fluid levels loose wiring or rusted or corroded hardware 2 Lack of proper maintenance as outlined in the electric vehicle owner s manual 3 Damages caused by improper installation of the Computer or Controller 4 Vehicles charged by systems other than the recommended CLUB CAR Charger Without limiting the generality of the foregoing in any way and as part of its limited warranty exclusion CLUB CAR does not warrant that the Computer or Controller is suitable for use in any application other than its recommended CLUB CAR products As in the use of any battery operated device a prudent owner will read and study the charger owner s manual the electric vehicle owner s manual the operator instructions and the battery warning labels and will exercise due care in working on or around batteries Transportation expenses for warranty services are also excluded from this warranty WARRANTY LIMITATIONS CLUB CAR s liability under this limited warranty shall be to replace a defective Computer or Controller Replacement shall be furnishing a new or reconditioned Computer or Controller that is identical or reasonably equivalent to the warranted product at no cost to the purchaser during the four year limited warranty period for commercial use or 4 years or 16 000 energy units whichever occurs first except for transportation expenses All
20. T 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 VEHICLE TO CAUSE IT TO PERFORM OUTSIDE CLUB CAR SPECIFICATIONS THE WARRANTY IS LIKEWISE VOID IF THE VEHICLE INVOLVED SHOWS INDICATIONS THAT REASONABLE OR NECESSARY MAINTENANCE AS OUTLINED IN THE OWNER S MANUAL AND MAINTENANCE AND SERVICE MANUAL WAS NOT PERFORMED AT THE TIME AND IN THE MANNER SPECIFIED IN SUCH MANUALS SOLE REMEDY CLUB Car s liability under this limited warranty or in any action whether based upon warranty contract negligence strict product liability or otherwise shall be the repair or replacement at CLUB Car s option of the vehicle or component thereof that CLUB CAR deems to be defective Replacement shall mean furnishing during the applicable limited warranty period a new vehicle or factory reconditioned vehicle or component thereof that is identical or reasonably equivalent to the warranted product or component 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 If CLUB CAR elects to repair the vehicle it may provide factory reconditioned parts or components All parts and components replaced under warranty shall become the property of CLUB CAR HOW TO MAKE A WARRANTY CLAIM To make a warranty claim under this limited warran
21. Y CCI 101908601 Decal Safety Reflector Front Decal Safety Reflector Rear 3 Point Seat Belt Decal Tow Run Switch Warning on Tow Run 1 101908601 switch plate under seat Decal Component Cover Caution on electrical 2 101931501 component cover 102313104 Decal Vehicle Identification Number VIN EX IAN res AAA 6 Turn Signal Light Page 8 Villager LSV Owner s Manual Safety Decal and Feature Identification VILLAGER 2 2 LSV OPERATING INSTRUCTIONS Read Owner s Manual and warnings prior to driving d contr Environmental Performance tu This vehicle s are turned in desired direct 7 Has a maximum speed of greater than 20 miles per hour mph Jolect a ndana choose vehicles wiki higher geome but not greater than 25 mph VEHICLE DISCLOSURE Global Warming Score Smog Score Shall only be operated in the manner and locations permitted by law 10 10 Shall not be operated on a public highway with a speed limit in excess o OOOO Ona ator pedal is pressed of 35 mph provided the maximum posted speed limit for lawful Clement hongo Chaneat elerator pedal and press brake pedal operation in Maryland is 30 mph and the limit for Idaho is 25 mph an le May be a hazard on the roadways if it impedes traffic Using a rrativa fuel may improve scores See www DriveCiean ce gov a j A itati impedi E erica emission are a primary conil to global warming and smog May subject the driver to c
22. accelerator pedal and press the brake pedal until vehicle comes to a complete stop PARKING AND LEAVING THE VEHICLE 1 After stopping vehicle firmly press the park brake pedal until it locks Make sure it is fully engaged 2 Turn the key switch to the OFF position and place the Forward Reverse switch in the NEUTRAL position Remove the key when the vehicle is not in use When the Tow Run switch is in the RUN position with the Forward Reverse switch or key switch in any position the walk away braking function is designed to prevent the vehicle from rolling at more than 1 to 3 mph 1 5 to 4 8 km h on slopes of less than 20 unless the accelerator is pressed TRANSPORTING ON A TRAILER A WARNING e Do not allow riders in the trailer being towed Avoid sudden starts sudden stops and tight turns when towing WARNING CONTINUED ON NEXT PAGE Page 28 Villager LSV Owner s Manual Storage 4 WARNING e Avoid stopping on a hill when towing If you must stop on a hill avoid sudden starts or rolling backwards and stopping suddenly Failure to heed this warning could cause the vehicle to overturn possibly resulting in severe personal injury e Reduce normal driving speed when transporting a Club Car vehicle on a trailer Do not tow a Club Car vehicle behind a passenger vehicle or truck on a public road unless it is on an approved trailer For use on public roads the trailer must meet all federal state and local requ
23. ace battery wires e If battery wire terminals are damaged or corroded replace or clean them as necessary Failure to do so may cause them to overheat during operation and could result in a fire property damage or personal injury 1 Batteries should be kept clean and free of corrosion Wash tops and terminals of batteries with a solution of baking soda and water 1 cup baking soda 237 mL per gallon 3 8 L of water Rinse solution off batteries Do not allow this solution to enter the battery Be sure terminals are tight Let the terminals dry and then spray them with Battery Terminal Protector Spray CC P N 1014305 See following NOTE NOTE Dispose of waste water properly 2 The electrolyte level in the batteries should be checked weekly Figure 14 Add distilled water only after charging unless the electrolyte level is below the top of the plates In this case add just enough distilled water to cover the plates charge and then check the level again Never charge batteries if plates are exposed above electrolyte level For best battery life use only distilled water See following CAUTION and NOTE 1 Level Indicator 2 Cap 3 Plates Electrolyte level at least 1 2 inch 13 MM above plates or to level indicator Figure 14 Electric Battery Electrolyte Level A CAUTION e Do not overfill the batteries NOTE A battery watering gun or bottle is available at many auto parts deale
24. age 9 4 If the charger cannot remain plugged in AC power will not be available during extended storage or electrolyte levels will not be maintained then disconnect the batteries for storage Figure 1 Page 13 RETURNING THE STORED VEHICLE TO SERVICE 1 If necessary connect batteries See Connecting the Batteries Electric Vehicles on page 13 2 Fully charge batteries 3 Adjust tires to recommended tire pressure See Vehicle Specifications on page 44 4 Perform the Pre Operation and Daily Safety Checklist on page 25 and the Performance Inspection on page 25 MAINTENANCE See General Warnings on page 11 To ensure trouble free vehicle performance it is very important to follow an established preventive maintenance program Regular and consistent vehicle maintenance can prevent vehicle downtime and expensive repairs that can result from neglect Use the Pre Operation and Daily Safety Checklist on page 25 the Performance Inspection on page 25 and the following Periodic Service Schedule and Periodic Lubrication Schedule to keep the vehicle in proper working condition Page 30 Villager LSV Owner s Manual Periodic Service Schedule 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 due to unsafe conditions Contact your local Club Car distributor dealer to perform all repairs and semiannual and annual
25. as applicable D431018 D436557 D442402 D444328 D449806 DES 271008 DES 292899 DES 354264 DES 394617 DES 409296 4343503 4539162 4637270 4821827 4826467 5042519 5083736 5403240 5543243 5565760 5788255 5857692 5915495 6087805 6114833 6170787 6186584 6209796 6213145 6314632 and other patents pending 1012647 VEHICLE EMISSION CONTROL INFORMATION This vehicle is certified t0 CLUB CAR INC operate on stored eleciric energy This vehicle conforms to California regulations applicable to YYYY Model Year new ZEV passenger cars Test Group YIRC00000002 Decal Operating Instructions on wiper motor 1 1012647 Decal Patent 103757901 cover Vi COPEC 7 ono paten charger Gand pre estore oca vei isons como eaten ra Sow ov venae Waring ange Decal Vehicle Disclosure under canopy on driver 103537001 sida 14 License Plate Holder i 7 103593401 Decal Environmental Performance pas 3rd Brake Light e 103756501 Decal Collision Rollover or Falling Off Warning fief Reverse Light Villager LSV Owner s Manual Page 9 Safety Decal and Feature Identification VILLAGER 2 2 LSV FALLING OUT COULD RESULT IN SEVERE INJURY OR DEATH Two 2 persons per bench seat maximum Fasten seat belt and remain seated while moving Hold on and keep entire body inside vehicle at all times Never stand in front of or behind vehicle Do not leave children unattended in vehicle at any tim
26. ce instructions in this manual Your safety and comfort are important to us so we urge you to read and follow the step by step operating instructions and safety procedures in this manual These instructions must be followed in order to avoid the risk of severe personal injury If you rent or loan your vehicle to others we recommend that you ask them to read this manual before they operate the vehicle Club Car products are backed by a customer support system designed to offer you fast courteous service In the event your Club Car vehicle needs repairs or service please contact your local authorized Club Car dealer or distributor he will be able to provide technical advice perform warranty work and sell parts and service manuals For the name and address of the authorized Club Car dealer or distributor nearest you logon to our web site at www clubcar com or call 1 800 ClubCar 258 2227 If you would prefer to write to us direct your letter to Club Car Attention Marketing Services P O Box 204658 Augusta Georgia 30917 4658 USA We hope you will consider this owner s manual a permanent part of your Club Car vehicle If you sell the vehicle please include the manual so that the next owner will have the important operating safety and maintenance information it contains To obtain additional copies of this manual reference website telephone and address information above REGULAR MAINTENANCE ITEMS Battery Terminal Protector Spray CC
27. cm 91 5 in 232 cm 101 in 254 cm Overall length Overall length with Bed Box Overall width 47 3 in 120 cm 47 3 in 120 cm Overall height with canopy 68 5 in 174 cm 68 5 in 174 cm Wheelbase 65 5 in 166 cm 65 5 in 166 cm Ground clearance 4 5 in 11 cm 4 5 in 11 cm 34 5 in 88 cm 34 5 in 88 cm Front wheel tread Overall height at steering wheel 48 in 122 cm 48 in 122 cm Rear wheel tread 1129 Ib 512 kg 1069 Ib 486 kg Vehicle rated Capacity level surface only 800 Ib 363 kg 550 Ib 250 kg Weight vehicle with canopy and batteries Al 38 5 in 98 cm 38 5 in 98 cm ol Weight GVWR 1930 Ib 875 kg 1619 lb 735 kg Forward speed Standard maximum 25 mph 40 km h 25 mph 40 km h Outside clearance circle diameter 17 ft 6 in 533 cm 17 ft 6 in 533 cm Page 44 Villager LSV Owner s Manual Vehicle Specifications SPECIFICATIONS VILLAGER 2 2 Turning radius per SAE J 695 68 in 173 cm Intersecting aisle clearance radius 77 in 196 cm Floorboard height 11 8 in 30 cm Seat height 29 5 in 75 cm BED BOX Overall Length 31 4 in 80 cm Width 37 9 in 96 cm Height 9 3 in 24 cm STANDARD SEATING CAPACITY LIQUID CAPACITIES Transaxle 22 oz 0 67 liters 22 oz 0 67 liters TIRE PRESSURE Standard Front and rear 215 60 R8 with 8x7 steel rims 35 psi 241 kPA 35 psi 241 kPA Alloy Option Front and rear 205 50 R10 w
28. d Front Suspension in the maintenance and service manual Check for loose hardware cracks or other Motor Controller Output Regulator COR Annual service by trained technician only If batteries are not performing as expected or every 100 hours of operation whichever Batteries see Batteries in the maintenance and service comes first manual Page 32 Villager LSV Owner s Manual Periodic Lubrication Schedule PERIODIC LUBRICATION SCHEDULE PERIODIC LUBRICATION SCHEDULE LUBRICATION REGULAR INTERVAL SERVICE POINTS RECOMMENDED LUBRICANT Brake pedal shaft bearings Dry Moly Lube CC P N 1012151 Brake Linkage and pivots Or Dry Moly Lube CC P N 1012151 Semiannually by owner or i trained technician or every 50 Accelerator pivot rod supports Dry Moly Lube CC P N 1012151 hours of operation whichever Charger Receptacle if so equipped Or WD 40 comes first Brake Slides Dry Moly Lube CC P N 1012151 Front suspension 2 fittings Or Chassis Lube EP NLGI Grade 2 ici 22 oz 0 67 liters SAE 30 WT API Class Annually by trained technician Check fill transaxle to plug level O zi iters i i only or every 100 hours of SE SF or SG Oil or higher operation whichever comes Inspect front wheel bearings Repack O Braes GES EP NEGI CodeS first as necessary
29. d and that there is adequate ventilation 4 WARNING e Vehicles with a charger receptacle Never modify wiring to bypass the gray sense lead fuse CHARGING BATTERIES NOTE When temperatures fall below 65 F 18 3 C batteries charged in unheated areas should be placed on charge as soon as possible after use Batteries are warmest immediately after use while cold batteries require more time to fully charge Insert the onboard charger AC plug into a dedicated AC receptacle that is properly grounded and wired in accordance with the National Electric Code and all local codes and ordinances The charger will turn on two to ten seconds later The battery charger interacts with the vehicle onboard computer The computer records the amount of energy consumed during vehicle use While the charger is plugged in the vehicle s control circuit is locked out preventing operation of the vehicle as well as the possibility of subsequent damage to the charger and vehicle Once the lockout is actuated the charger turns on The onboard computer then records the amount of energy being returned to the batteries When the optimum amount of energy needed to replenish the batteries is returned the charger will turn off The control circuit lockout remains activated until the charger plug is disconnected from the vehicle As long as the charger is allowed to shut off by itself the batteries will be fully charged Overcharging and undercharging will n
30. d fine grade No 00 steel wool Club Car does not recommend any type of pressure washer or steam cleaning Such a process will expose electrical components to moisture Moisture entering electrical components can result in water damage and subsequent component failure Use non abrasive wax products Battery acid fertilizers tars asphalt creosote paint or chewing gum should be removed immediately to prevent possible stains The seats of the vehicle will last longer with proper cleaning Use a solution of 10 liquid soap and warm water applied with a soft cloth For imbedded dirt a soft bristle brush may be used For heavy soiling difficult stains or scratches blemishes or other body damage see the Maintenance and Service Manual NOTE Dispose of waste water properly ACCESSORIES There is a complete line of accessory equipment available from Club Car and our dealers distributors You can obtain the name and phone number of your closest Club Car contact by visiting our web site at www clubcar com and clicking the Dealer Locator link Care should be taken that these accessories are properly installed by trained technicians and they are used in the manner for which they were designed See following WARNING A WARNING e Custom cab assemblies weatherproof enclosures door kits and tinted windshields will not protect occupants from flying objects e Modifications to the vehicle must not compromise compliance with state o
31. d precautions must be used when performing maintenance service or accessory installation Place Tow Run switch in the TOW position before disconnecting or connecting the batteries Failure to heed this warning could result in a battery explosion or severe personal injury To avoid unintentionally starting an electric vehicle disconnect the batteries and discharge the controller See Disconnecting the Batteries Electric Vehicles on page 13 Ensure battery connections are clean and properly tightened See Battery Care Water Quality on page 34 Use only 4 gauge AWG wires with low resistance terminals to replace battery wires on the vehicle 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 batteries Do not wear loose clothing or jewelry such as rings watches chains etc when servicing the vehicle or battery charger Use insulated tools when working near batteries or electrical connections Use extreme caution to avoid shorting of components or wiring DISABLING THE VEHICLE 1 2 Set the park brake Turn the key switch OFF and remove the key Page 12 Villager LSV Owner s Manual General Warnings 3 Place the Forward Reverse control in the NEUTRAL position 4 In addition chock the wheels if servicing or repairing the vehicle DISCONNECTING THE BATTERIES ELECTRIC VEHICLES 1 Disable the vehicle S
32. date of purchase The terms of this limited four year warranty shall be as follows Free replacement with respect to parts and labor for such battery as set forth below subject to the terms and conditions contained herein BATTERY CONFIGURATION 6 VOLT STANDARD DUTY DEEP CYCLE BATTERIES within 4 years or 18 000 energy units whichever first occurs from date of purchase 6 VOLT HEAVY DUTY DEEP CYCLE BATTERIES within 4 years or 20 000 energy units whichever first occurs from date of purchase 8 VOLT STANDARD DUTY DEEP CYCLE BATTERIES within 4 years or 16 000 energy units whichever first occurs from date of purchase The battery should be returned to an authorized CLUB CAR distributor or dealer with evidence of proof of purchase date CLUB CAR reserves the right to test and recharge any battery returned for adjustment LIMITED WARRANTY EXCLUSIONS THE PROVISIONS OF THIS LIMITED WARRANTY SHALL NOT APPLY TO FAILURE DUE TO Abuse such as overcharging undercharging improper fluid levels loose wiring or rusted or corroded hardware Lack of proper maintenance as outlined in the electric vehicle owner s manual Damages caused by improper installation of the battery Neglect breakage freezing fire explosion wreckage the addition of any chemical or the operation of the battery in an uncharged condition below half charge 1 200 specific gravity 5 A battery damaged by a defective charger Without limiting the generality of th
33. dic Service Schedule PERIODIC SERVICE SCHEDULE REGULAR INTERVAL SERVICE See Pre Operation and Daily Safety Pre Operation and Daily Safety Checklist F Checklist on page 25 Daily service by owner 5 Performance Inspection See Performance Inspection on page 25 Batteries Charge batteries after each daily use only i Check electrolyte level Add water if Weekly service by owner Batteries necessary See page 36 Wash battery tops and clean terminals with baking soda water solution Monthly service by owner or trained Tires Check air pressure and adjust if necessary i technician See Vehicle Specifications on page 44 f Wash battery compartment and underside of General vehicle f vehicle Check brake shoes replace if necessary or adjust as required Batteries See Wheel Brake Assemblies Section in the appropriate maintenance and service manual Brake system Lubricate brake slides per Lubrication Schedule See Wheel Brake Assemblies Section in the appropriate maintenance F is and service manual Semiannual service by trained technician only or every 50 hours of operation Check brake cables for damage replace if whichever comes first necessary Electrical wiring and connections Check for tightness and damage Check condition of contacts and wire Forward Reverse switch f i connections make sure connections are tight Check and adjust as required See Steering Front wheel alignment and camber an
34. e Children requiring a child safety seat must not ride in vehicle BAT A 201705702 NOTICE Do not operate vehicle without this cover properly installed Do not direct water stream in this area will cause damage to components See vehicle maintenance and service manual before servicing g MFD BY CLUB CAR INC GVWR 1930 LBS 875 KG GAWR FRONT 445 LBS 201 KG REAR 1485 LBS 674 KG RIMS 8X7 TIRES 215 60 R8 95 PSI TOW RUN Tus vente conronus DERA gt Place Tow Run switch in TOW position before FAILURE TO HEED THIS SHOWS ABOVE Disconnecting or connecting batteries WARNING COULD RESULT LOW SPEED VEHICLE os da IN A BATTERY EXPLOSION o o E A OR SEVERE PERSONAL g INJURY cel 101908601 Decal Falling Off Warning on rear facing seat 1 101705702 7 hand rail 2 101908601 Decal Tow Run Switch Warning on Tow Run switch plate under seat Decal Component Cover Caution on electrical 3 101931501 component cover Turn Signal Light Decal Safety Reflector Front UN Decal Safety Reflector Rear 3 Point Seat Belt 102313102 Decal Vehicle Identification Number VIN EA Interior Rear View Mirror E C El Page 10 Villager LSV Owner s Manual Safety Details SAFETY DETAILS 4 WARNING e This owner s manual should be read completely before attempting to drive or service the vehicle Failure to follow the instructions in this manual could result in property damage severe p
35. e vehicle in the forward direction or press the REVERSE side of the switch to operate the vehicle in reverse When the rocker switch is positioned in NEUTRAL with neither side down the vehicle will not operate if the accelerator pedal is pressed The reverse buzzer will sound as a warning when the Forward Reverse switch is in the REVERSE position 529 eps Figure 5 Instrument Panel Villager LSV Owner s Manual Page 17 Controls and Indicators BATTERY WARNING LIGHT These vehicles feature a dash mounted warning light 4 above steering column that when the vehicle is in operation indicates low battery voltage or when the vehicle is being charged indicates a charging problem Figure 5 The battery warning light is controlled by the onboard computer When the vehicle is in operation the warning light is designed to illuminate and remain illuminated if e Batteries voltage drops below 48 when there is no load on the batteries the vehicle is stopped and there are no accessories on e Batteries have discharged to less than 25 of rated capacity If the warning light illuminates when the vehicle is operating there should be enough power remaining to drive the vehicle for approximately 30 minutes However the vehicle should be charged at the first opportunity If the warning light illuminates and the vehicle is unable to operate for 30 minutes have your Club Car distributor d
36. e foregoing in any way and as part of its limited warranty exclusion CLUB CAR does not warrant that its battery is suitable for use in any application other than in its products As in the use of any battery a prudent owner will read and study the charger owner s manual the electric vehicle owner s manual the operator instructions and the battery warning labels and will exercise due care in working on or around batteries Transportation expenses for warranty services are also excluded from this warranty WARRANTY LIMITATIONS CLUB CAR s liability under this limited warranty shall be to replace a defective battery Replacement shall be furnishing a new or used battery with sufficient life to complete the remainder of the warranty term which is identical or reasonably equivalent to the warranted product at no cost to the purchaser during the four years or prescribed energy units warranty period whichever first occurs All batteries which are replaced under this limited warranty become the property of CLUB CAR THIS LIMITED WARRANTY IS EXCLUSIVE CLUB CAR MAKES NO OTHER WARRANTY OF ANY KIND EXPRESSED OR IMPLIED ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS OR TIME LIMITS STATED IN THIS WARRANTY ARE HEREBY DISCLAIMED BY CLUB CAR AND EXCLUDED FROM THIS WARRANTY THE PURCHASER AND CLUB CAR EXPRESSLY AGREE THAT THE REPLACEMENT OR REPAIR OF THE DEFECTIVE VEHICLE OR COMPONENT THEREOF IS T
37. ealer check the vehicle for a possible battery or electrical system problem When the batteries receive an incomplete charge because 1 AC power to the charger is interrupted 2 automatic charger shut off occurs after 16 hours of operation 3 the charger malfunctions or 4 the wrong charger is used the warning light will indicate as follows The warning light will not come on if the charge is 90 or more complete The onboard computer will retain in memory the amount of charge needed to fully replenish the batteries and will complete the charge during the next charge cycle When the charger is unplugged the warning light will illuminate and remain illuminated for 10 seconds if the charge is less than 90 complete but the vehicle has enough power for approximately 30 minutes of operation This will alert the operator that the vehicle may be used but that it must be charged to completion as soon as possible The warning light will repeatedly illuminate for 10 seconds with 4 second intervals if the charger times out at 16 hours and the batteries are not sufficiently charged See battery charger owner s manual This indicates an abnormal charge cycle The charger and batteries should be checked by your Club Car distributor dealer The warning light will repeatedly illuminate for 10 seconds with 4 second intervals during a charge cycle DC plug is still connected if AC power to the charger is interrupted The light will go out when AC power is
38. edal with your right foot Figure 7 78 79 eps Figure 7 Brake Pedal Figure 8 Park Brake Pedal 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 and the words PARK BRAKE marked on top Figure 7 To set the park brake press the brake pedal firmly and tilt the park brake portion of the pedal forward Figure 8 To disengage apply pressure to the brake pedal See following WARNING 4 WARNING e The park brake will release when the brake pedal is pressed The park brake has multiple locking positions and should be firmly pressed and locked to prevent the vehicle from rolling NOTE The brake lights will illuminate when the park brake is engaged unless the key switch is in the OFF position TOW RUN SWITCH 4 WARNING e Place Tow Run switch in the TOW position before disconnecting or connecting the batteries Failure to heed this warning could result in a battery explosion or severe personal injury e When the Tow Run switch is in the TOW position all motor braking functions including walk away braking are disabled Electric vehicles are equipped with a Tow Run switch 1 located on the seat support panel under the seat Figure 9 The switch must be in the RUN position in order to operate the vehicle When the switch is in the TOW position power to the vehicle electrical components is turned off and the vehicle will not operate See
39. ee Disabling the Vehicle on page 12 2 Place Tow Run switch in the TOW position before disconnecting or connecting the batteries Failure to heed this warning could result in a battery explosion or severe personal injury 3 Disconnect the batteries negative cable first as shown Figure 1 4 After disconnecting the batteries wait 90 seconds for the controller capacitors to discharge Viewed from driver side of vehicle 1 Place TOW RUN Switch in TOW before disconnecting or connecting battery cables 2 Remove negative battery cable 3 Remove positive battery cable Connect battery cables in reverse order 1436 eps Figure 1 Battery Cable Removal 6x8 Volt Battery Configuration CONNECTING THE BATTERIES ELECTRIC VEHICLES Ensure the Tow Run switch is in the TOW position Connect the battery cables positive cable first Tighten battery terminals to 110 in lb 12 4 N m Coat terminals with Battery Terminal Protector Spray CC P N 1014305 to minimize corrosion Oa gt Villager LSV Owner s Manual Page 13 General Warnings RECYCLING LEAD ACID BATTERIES A WARNING e Lead acid batteries contain lead Pb other metals acids and other compounds If improperly handled they can contaminate both water and soil causing environmental damage and personal injury Lead acid batteries are identified by the symbol shown below and should be properly recycled Figure 2 They cannot be disposed as munici
40. ems such as the charger plug and receptacle brake shoes belts brushes bushings mats and pads maintenance adjustments cosmetic deterioration and items which deteriorate or fail due to exposure or ordinary wear and tear Batteries battery charger onboard computer and solid state speed controller are covered under separate CLUB CAR warranties Also excluded from any CLUB CAR warranty is damage to a vehicle or component resulting from a cause other than a defect including unreasonable or unintended strain or use improper installation of accessories installation of parts or accessories that are not original equipment overloading accident alteration abuse or neglect Without limiting the generality of the foregoing in any way and as part of its limited warranty exclusion CLUB CAR does not warrant that the original Club Car components are suitable for use in any application other than its products As in the use of any electrical device a prudent owner will read and study the charger owner s manual the electric vehicle owner s manual the operator instructions and the battery warning labels and will exercise due care in working on or around electrical devices Transportation expenses for warranty services are also excluded from this warranty VOIDING OF WARRANTY Page 46 Villager LSV Owner s Manual Warranties THIS AND ANY OTHER WARRANTY SHALL BE VOID IF THE VEHICLE IS ABUSED OR USED IN AN UNINTENDED MANNER OR SHOWS INDICATIONS THA
41. er side cup holder or above the accelerator or brake pedal Example PHO901 583947 Figure 4 The two letters 1 at the beginning of the serial number indicate the vehicle model The following four digits 2 indicate the model year and production week during which the vehicle was built The six digits 3 following the hyphen represent the unique sequential number assigned to each vehicle built within a given model year See following NOTE NOTE Have the vehicle serial number available when ordering parts or making inquiries Build Code The build code 4 is a five digit number that appears on the vehicle serial number decal The build code exists to enable the user to identify the correct owner s manual for a vehicle This owner s manual is valid for the build code range indicated on the back cover of this owner s manual A SERIAL NUMBER gt PHO901 1 23456 BC54679 1400 eps Figure 4 Serial Number Decal VEHICLE IDENTIFICATION NUMBER VIN AND CERTIFICATION LABEL The vehicle identification number VIN is located on the top of the dash panel The VIN certification decal is located underneath the canopy in view of the driver See Safety Decal and Feature Identification on page 6 CONTROLS AND INDICATORS See General Warnings on page 11 4 WARNING e The vehicle should be operated by an adult who possesses an unrestricted driver s license issued by the State in which the vehicle will be operated Before all
42. ersonal injury or death It is important to note that some vital statements throughout this manual and on the decals affixed to the vehicle are preceded by the words DANGER WARNING or CAUTION For your protection we recommend that you take special notice of these safety precautions Safety precautions are essential and must be followed 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 injury or death To obtain replacement decals or for questions regarding placement please contact your distributor dealer 4 DANGER e A DANGER indicates an immediate hazard that will result in severe personal injury or death 4 WARNING A WARNING indicates an immediate hazard that could result in severe personal injury or death 4 CAUTION e A CAUTION with the safety alert symbol indicates a hazard or unsafe practice that could result in minor personal injury CAUTION e A CAUTION without the safety alert symbol indicates a potentially hazardous situation that could result in property damage GENERAL WARNINGS The following safety statements must be heeded whenever the vehicle is being operated repaired or serviced See Safety Decal and Feature Identification on page 6 Other specific safety statements appear throughout this manual and on the vehicle A DANGER e Battery Explo
43. 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 allow 10 seconds to elapse before operating the vehicle Page 20 Villager LSV Owner s Manual Controls and Indicators The Tow Run switch should be placed in the TOW position under the following conditions Before Towing the Vehicle Place the Tow Run switch in the TOW position to disable all motor braking functions thus preventing possible damage that could occur to the vehicle or electrical components if the vehicle is towed while the walk away braking function is operating e Before Disconnecting or Connecting Battery Cables Place the Tow Run switch in the TOW position to turn off power to the vehicle electrical system thus preventing severe arcing and possible battery explosion as the battery cables are disconnected For Long Term Storage Place the Tow Run switch in the TOW position to turn off power to the vehicle electrical system thus preventing vehicle electrical components from discharging the batteries 7A 1819 Figure 9 Tow Run Switch Figure 10 Turn Signal Lever Hazard Lights Horn and Speedometer HEADLIGHTS TAILLIGHTS The light switch 3 is located on the instrument panel to the right of the steering column Figure 5 Press the side of the switch with the headlight symbol to turn the lights on and press the o
44. hase by the Original Retail Purchaser This limited warranty covers material workmanship and repair labor cost as to those items specifically listed above for the periods specified determined by customer use application Such repair labor shall be performed only by CLUB CAR its authorized dealers or a service agency approved by CLUB CAR IF THE WARRANTY REGISTRATION FORM IS NOT COMPLETED AND RETURNED TO CLUB CAR AT THE TIME OF THE ORIGINAL RETAIL SALE PURCHASER MUST PROVIDE PROOF OF DATE OF PURCHASE WITH ANY WARRANTY CLAIM LIMITED WARRANTY EXCLUSIONS THE PROVISIONS OF THIS LIMITED WARRANTY SHALL NOT APPLY TO FAILURE DUE TO A Abuse or neglect such as overcharging undercharging improper battery fluid levels loose wiring or rusted or corroded hardware B Lack of proper maintenance as outlined in the LSV vehicle owner s manual C Damages caused by improper installation of a component D Vehicles charged by systems other than the CLUB CAR Charger E Neglect breakage freezing fire explosion wreckage the addition of any chemical or the operation of the battery in an uncharged condition below half charge 1 200 specific gravity F Semiconductor parts such as diodes and fuses which are vulnerable to electrical overloads including lightning beyond the control of CLUB CAR Excluded from any CLUB CAR warranty are all fuses filters decals except safety decals light bulbs lubricants trim pieces seats routine wear it
45. hicle has a defect which could cause a crash or could cause injury or death you should immediately inform the National Highway Traffic Safety Administration NHTSA in addition to notifying Club Car LLC If NHTSA receives similar complaints it may open an investigation and if it finds that a safety defect exists in a group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in individual problems between you your dealer or Club Car LLC To contact NHTSA you may call the Vehicle Safety Hotline toll free at 1 888 327 4236 TTY 1 800 424 9153 go to http www safercar gov or write to Administrator NHTSA 400 Seventh Street SW Washington DC 20590 You can also obtain other information about motor vehicle safety from http www safercar gov Villager LSV Owner s Manual Page 5 Safety Decal and Feature Identification SAFETY DECAL AND FEATURE IDENTIFICATION The following pages contain safety decal and feature identification information For detailed information on specific features read the appropriate section in this manual Page 6 Villager LSV Owner s Manual Safety Decal and Feature Identification VILLAGER 2 LSV x VEHICLE DISCLOSURE Read Owner s Manual and safety warnings prior to driving Study and understand controls e oi Environmental Performance ES e wheel et desired di FASTEN SEATBELT and romain seated W o Has a maximum speed of greater than 20 miles per hour mph Prolec
46. ill automatically activate the charger when necessary 9 2 If the battery charger is left plugged in during extended storage check the electrolyte level and charger function monthly to ensure that proper operation is maintained To check charger function disconnect the AC cord onboard charger from the power source wait five seconds then reconnect it The charger is functioning properly if the ammeter indicates current NOTE The OBC keeps track of the time spent in storage mode When the OBC detects that the storage charge cycles may have depleted the available electrolyte it will stop the charger from further operation Disconnecting then reconnecting the AC cord onboard charger indicates the electrolyte levels have been maintained and allows the OBC to resume operation While in storage the Tow Run switch should be in Tow When in Tow mode the amber battery warning light will not illuminate Do not attempt to use the battery light as an indication of battery state while in storage 9 3 If AC power is off for 7 days or longer the OBC will not function or charge the vehicle again until it has been restarted To restart the computer make sure AC power has been restored disconnect the AC cord onboard charger from the power source wait five seconds then reconnect it CAUTION e Be sure to check the batteries and charger monthly to maintain correct battery water level and to ensure the charger is operating correctly during stor
47. ipped with the Single Point Watering System the initial electrolyte level check on all battery cells verifies that all the valves in the SPWS are functioning correctly See Periodic Service Schedule on page 31 If a valve fails to open the cell will eventually dry out The initial one time inspection of all cells will identify any occurrence of a valve that fails to open If a valve fails to close it will become evident due to the cell overflowing during routine watering Either failure scenario is rare but should be monitored in the initial inspection and during routine watering sessions Replace malfunctioning valves to ensure maximum battery life See following CAUTION Villager LSV Owner s Manual Page 37 Battery Charger CAUTION After checking the electrolyte fully tighten the battery caps to prevent electrolyte leakage 2 After the initial six week inspection manually check the electrolyte level at least once per year particularly after long term storage or any other period of vehicle inactivity See preceding CAUTION BATTERY CHARGER 4 DANGER The charging area must be ventilated Hydrogen level in the air must never exceed 2 The total volume of air in the charging area must be changed five times per hour Exhaust fans should be located at the highest point of the roof Contact a local HVAC engineer Do not charge the vehicle batteries with the vehicle covered or enclosed Any enclosure or cover should be removed or u
48. irements such as taillights brake lights etc e The vehicle to be transported should be tied securely to the trailer with the Forward Reverse handle or switch in the NEUTRAL position the key switch in the OFF position and the park brake firmly engaged e Because of the added length of the trailer use caution when making turns e Do not transport the vehicle on a trailer with a load in the vehicle cargo bed e Secure the seats before transporting on a trailer If the vehicle must be transported over long distances or on public highways it should be transported on an approved trailer that has the following approved load rating per vehicle being transported Villager 2 LSV 1069 Ib 486 Kg Villager 2 2 LSV 1129 Ib 512 kg NOTE A two car trailer should be rated at Villager 2 LSV 2 x 1069 Ib 2138 Ib 2 x 486 kg 972kg Villager 2 2 LSV 2 x 1129 Ib 2258 Ib 2 x 512 kg 1024kg STORAGE See General Warnings on page 11 A WARNING e Turn the key switch to the OFF position remove the key and leave the Forward Reverse handle or switch in the NEUTRAL position during storage This is to prevent unintentionally starting the vehicle or a fire hazard Place Tow Run switch in the TOW position e Do not attempt to charge frozen batteries or batteries with bulged cases Discard the battery in accordance with all environmental laws or return to an authorized Club Car dealer Frozen batteries can explode A CAUTION
49. it seven segment display should indicated 20P while the small 5 digit seven segment display should indicate 0700 The values may be adjusted by selecting the applicable digit denoted by flashing using the select button and changing the value with the adjust button SEAT BELTS LSV vehicles are equipped with seat belts one for each occupant See following WARNING Page 22 Villager LSV Owner s Manual Seat Belts A WARNING The seat belts must be properly installed before operating the vehicle Club Car strongly urges that the vehicle s occupants be properly restrained at all times with the seat belts provided See Transporting Children on page 25 Pregnant women Consult your doctor for specific recommendations The seat belt should be worn securely and as low as possible over the hips and not on the waist Injured persons Depending on the injury first check with your doctor for specific recommendations Forward facing seats To secure the retractable seat belt sit up straight and well back in the seat Pull the seat belt out of the retractor and insert the tab into the buckle A click will be heard when the tab locks into the buckle Position the lap belt as low as possible on the hips not on the waist After inserting the tab make sure the tab and buckle are locked and that the belt is not twisted Make sure the shoulder belt is positioned across the center of the shoulder The belt should be kept away from the neck but no
50. itations for impeding traffic Scores are determined by the Cablcena Ak Resources Board baeed on UNINTENDED VEHICLE MOVEMENT MAY CAUSE SEVERE INJURY OR DEATH May not be equipped with such safety features as bumpers a padded tha wehide s measured enitons Pease vat Bacs pamate dashboard visors or a tamper resistant odometer ae a Average ew vane After stopping firmly set park br nd place Forward Reverse switch in NEUTRAL position Turn key OFF and remov n notin use 103757901 XXXXXX CT 5J5LD22Bx2A COLLISION ROLLOVER OR FALLING OFF MAY CAUSE SERIOUS INJURY OR DEATH BEFORE USING VEHICLE READ OPERATING INSTRUCTIONS Occupants must fasten seat belts and remain seated while moving Use CAUTION when operating vehicle in the presence of higher speed vehicles in congested areas or on unimproved surfaces Do not operate this vehicle in a manner that impedes traffic Only operate vehicle in compliance with local and state laws Never operate under the influence of alcohol or drugs Drive slowly in turns and straight up and down slopes Operate from driver side only Keep entire body inside vehicle and hold on to seat handle while moving Two 2 persons per bench seat maximum Children requiring a child safety seat must not ride on the vehicle Do not leave children unattended on vehicle wa This vehicle is covered by one or more of the following U S patents
51. ith 10x6 Alloy rims 30 psi 207 kPA 30 psi 207 kPA Villager LSV Owner s Manual Page 45 Warranties WARRANTIES CLUB CARO LIMITED WARRANTY FOR CARRYALL 8 VILLAGER LOW SPEED VEHICLES LSV 1 WARRANTY CLUB CAR LLC CLUB CAR hereby warrants to the Original Retail Purchaser that its new Model Carryall 8 Villager LSV purchased from CLUB CAR or an authorized Dealer the Vehicle shall be free from defects in material and workmanship under normal use and service for the periods stated below subject to the provisions limitations and exclusions contained in this non transferable limited warranty LIMITED TWO YEAR 2000 HOUR WARRANTY The electric motor transaxle assembly electric vehicle main frame assembly box bed hydraulic dump kit Cab assembly and doors of the Vehicle are warranted with respect to parts and labor against defects in material and workmanship for a period of two years or 2000 hours of operation whichever first occurs from the documented date of purchase by the Original Retail Purchaser LIMITED ONE YEAR 1000 HOUR WARRANTY All remaining components of the Vehicle not specified otherwise and all other original equipment options and accessories supplied by CLUB CAR or its authorized distribution channel are warranted with respect to parts and labor against defects in material and workmanship for a period of one year or 1000 hours of operation whichever first occurs from the documented date of purc
52. king condition and in conjunction with the Performance Inspection on page 25 and the Periodic Service Schedule on page 31 Any problems should be corrected by a Club Car distributor dealer or a trained technician e General All the parts should be in place and properly installed Be sure that all nuts bolts and screws are tight e Safety and information decals Check to ensure that all safety and information decals are in place See Safety Decal and Feature Identification on page 6 e Tires Check for proper tire pressure wear and damage If tires are worn or damaged replace then immediately Ensure replacement tires meet Federal Motor Vehicle Safety Standards FMVSS 109 and 119 requirements replacement tires must also have a DOT marking and be of the specified size See Vehicle Specifications on page 44 See Vehicle Specifications on page 44 e Batteries Check electrolyte to ensure that it is at its proper level Figure 14 Page 36 Check battery posts Wires should be tight and free of corrosion Charge batteries fully before first use of vehicle Charger cord and plug Visually inspect for cracks loose connections and frayed wiring Performance Inspection Inspect as instructed See Performance Inspection on page 25 A WARNING Be sure the plastic has been removed from the seat bottom before operating the vehicle Failure to do so may result in a fire property damage personal injury or death PERFORMANCE INSP
53. luence of alcohol or drugs To help avoid rolling over SLOW DOWN BEFORE MAKING SHARP TURNS e Only operate vehicle where permitted by law e Before using vehicle read operating instructions FASTEN SEAT BELT and remain seated while moving e Children requiring a child safety seat must not ride on the vehicle e Comply with state and local laws pertaining to child safety e Do not start vehicle until all occupants are seated e Two 2 persons per bench seat maximum e Operate from driver side only WARNING CONTINUED ON NEXT PAGE Page 4 Villager LSV Owner s Manual Proposition 65 State of California A WARNING e Keep entire body inside vehicle and hold on to seat handle or handrail at all times e Drive slowly in turns and straight up and down slopes e Do not leave children unattended on vehicle at any time e Never stand in front of or behind vehicle e Do not drive the vehicle under tree limbs bridges tunnels or other objects that are less than 80 inches from the ground e This vehicle is not intended to be used where risk of falling objects exist If your vehicle will be used in such an environment contact your local dealer PROPOSITION 65 STATE OF CALIFORNIA A WARNING e This product contains or emits chemicals or substances that have been determined by the state of California to cause cancer and birth defects or other reproductive harm REPORTING SAFETY DEFECTS If you believe that your ve
54. maintenance accident or alteration is excluded from this limited warranty Some states allow neither limitation on the duration of an implied warranty nor exclusions or limitations of incidental or consequential damages Therefore the above limitations or exclusions may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state For further information contact WARRANTY SERVICES CLUB CAR LLC P O Box 204658 Augusta Georgia 30917 4658 U S A 706 863 3000 Page 50 Villager LSV Owner s Manual NOTES BC55487 Publication Part Number 103700406 Edition Code 1009D1010C This manual is valid for vehicles with build codes between BC54699 and the one indicated at the top of this page CTE Club Car LLC Web www clubcar com P O Box 204658 Phone 1 706 863 3000 Augusta GA 30917 4658 1 800 ClubCar USA Intl 1 706 863 3000 Fax 1 706 863 5808
55. nzipped and pulled back when batteries are being charged An accumulation of hydrogen gas could result in an explosion A WARNING Only trained technicians should repair or service the charger Contact a Club Car distributor dealer Each charger should have its own dedicated 15 or 20 ampere separately protected circuit breaker or fuse single phase branch circuit in accordance with all applicable electrical codes for the location Be sure wire connections at the receptacle and fuse link are clean and tight Have worn cut or damaged power cords or wires replaced immediately Do not expose to rain or any liquid Keep the charger dry Do not use near fuels grain dust solvents thinners or other flammables Chargers can ignite flammable materials and vapors Connect the charger AC supply cord to a properly grounded three wire outlet of the proper voltage and frequency as shown on the charger Do not use an adapter to plug the charger with a three prong plug into a two prong outlet Improper connection of the equipment grounding conductor can result in a fire or an electrical shock An extension cord or electrical outlet must accept a three prong plug Extension cord should be a three wire No 12 AWG American Wire Gauge or no 14 British Standard Wire Gauge and be as short as possible no more than 12 feet 3 7 m The use of improper extension cord could result in fire or an electrical shock Do not operate the charger if it ha
56. of components or wiring e Ensure battery connections are clean and properly tightened See Battery Care Water Quality on page 34 e Use only 4 gauge AWG wires with low resistance terminals to replace battery wires on the vehicle CAUTION e Turn off all accessories before charging batteries NOTE Recycle 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 vehicles New batteries will not deliver their full capabilities until they have been discharged and recharged 20 to 50 times To obtain maximum service life from new batteries restrict the use of vehicles with new batteries to one hour of operation between charges for the first two months vehicle is in service Batteries should be fully charged before first use of new vehicle before first use of a vehicle after storage and before releasing vehicle for use each day BATTERY CARE WATER QUALITY To keep batteries in good working condition the purity of water used is very important Distilled water is quite pure and is the most common type of water used in batteries Other acceptable types are deionized water and water from reverse osmosis Ordinary tap water should not be used because it contains an excessive amount of impurities that will degrade battery performance Distilled water is produced by distillation a process in which
57. ormally be prevented Villager LSV Owner s Manual Page 39 Single Point Watering System SPWS Batteries should be put on charge even if they have been used for only a short time i e 10 minutes The charger is automatic and will turn off when batteries are fully charged If the charger does not seem to be operating properly or if the batteries seem weak contact a local Club Car distributor dealer SINGLE POINT WATERING SYSTEM SPWS The following procedures outline the use Club Car s approved in line deionizer system 4 WARNING e When replacing batteries in the Single Point Watering System place the battery cap from the new replacement battery onto the used battery being removed from the car Important safety warnings on the battery cap must remain with the battery after it has been removed from the car CAUTION e Water the batteries only AFTER charging Use only the water deionizer equipment CC P N AM1240701 to water batteries with the SPWS WATERING BATTERIES WITH THE SPWS Checking the Water Flow Rate 1 Connect the 10 foot water hose from the deionizer with the built in screen filter 2 to the water faucet 1 Figure 15 See following CAUTION CAUTION e Make sure the screen filter is clean e Do not use a longer supply hose than provided with the deionizer system 20 feet as a decrease in water pressure could overfill the batteries and damage the refill system 2 Before screwing the hose end assembly
58. owing anyone to drive the vehicle make sure the driver is familiar with all controls and operating procedures Do not shift the Forward Reverse switch while the vehicle is in motion To avoid injury to an unsuspecting passenger or damage to the vehicle always bring the vehicle to a full stop before shifting the switch WARNING CONTINUED ON NEXT PAGE Page 16 Villager LSV Owner s Manual Controls and Indicators 4 WARNING e Release the accelerator pedal and then press the brake pedal firmly until the vehicle stops To avoid unintentionally starting or rolling the vehicle set the park brake place the Forward Reverse switch in the NEUTRAL position turn the key switch to the OFF position and remove the key when leaving the vehicle e Any modification to the vehicle that affects the stability or handling of the vehicle or increases maximum vehicle speed beyond factory specifications could result in severe personal injury or death KEY SWITCH The key switch 1 is mounted on the dash to the right of the steering column Figure 5 This vehicle is equipped with a two position pedal start key switch NOTE The key can be removed only when the key switch is in the OFF position FORWARD REVERSE CONTROL The Forward Reverse rocker switch 2 is located on the right hand side of the instrument panel Figure 5 The F FORWARD and R REVERSE positions are clearly marked Press the FORWARD side of the switch to operate th
59. pal waste and must be collected separately Responsibility for environmental protection must be shared not only by the manufacturers of the batteries 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 2 Dispose of Lead acid Batteries Properly INTERNATIONAL SAFETY SYMBOLS ON BATTERIES Anyone using repairing or servicing the vehicle must understand and heed the safety symbols on the vehicle battery or batteries eS AA 1 Shield eyes 3 No smoking no open flames no sparks 5 Battery acid hazard 2 Read and follow operating instructions 4 Keep away from children 6 Explosive gas hazard Refer to General Warnings for more information 1642 Figure 3 International Safety Symbols on Batteries Page 14 Villager LSV Owner s Manual General Information GENERAL INFORMATION This manual features the Villager Low Speed Vehicle This vehicle utilizes the IQ System 48 volt electric system Throughout this manual important features unique to each model are highlighted We urge the owner operator to read and understand this manual and to pay special attention to the features specific to their vehicle s Villager LSV Owner s Manual Page 15 Model Identification MODEL IDENTIFICATION The serial number of each vehicle is printed on a bar code decal mounted either below the passeng
60. parts and components replaced under this limited warranty become the property of CLUB CAR THIS LIMITED WARRANTY IS EXCLUSIVE CLUB CAR MAKES NO OTHER WARRANTY OF ANY KIND EXPRESSED OR IMPLIED ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS OR TIME LIMITS STATED IN THIS WARRANTY ARE HEREBY DISCLAIMED BY CLUB CAR AND EXCLUDED FROM THIS WARRANTY THE PURCHASER AND CLUB CAR EXPRESSLY AGREE THAT THE REPLACEMENT OR REPAIR OF THE DEFECTIVE VEHICLE OR COMPONENT THEREOF IS THE SOLE REMEDY OF THE PURCHASER CLUB CAR MAKES NO OTHER REPRESENTATION OR WARRANTY OF ANY KIND AND NO REPRESENTATIVE EMPLOYEE DISTRIBUTOR OR DEALER OF CLUB CAR HAS THE AUTHORITY TO MAKE OR IMPLY ANY REPRESENTATION PROMISE OR AGREEMENT WHICH IN ANY WAY VARIES THE TERMS OF THIS WARRANTY Villager LSV Owner s Manual Page 49 Warranties This computer or controller is intended to be used only in CLUB CAR PowerDrive System electric vehicles Any other use renders the Limited Warranties expressed herein and all implied warranties null and void and same are hereby excluded ALSO EXCLUDED FROM THIS LIMITED WARRANTY ARE ANY AND ALL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING BUT NOT LIMITED TO LOSS OF USE OR REVENUE LOSS OF TIME INCONVENIENCE OR ANY OTHER ECONOMIC LOSS Damage not resulting from a defect in material or workmanship or that occurs due to abuse or neglect including failure to provide reasonable and necessary
61. peration of the accelerator pedal differs from that of an automobile These vehicles use a special electrical system which employs motor braking in 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 vehicle without locking the park brake The vehicle will roll at about 1 3 mph 1 5 to 4 8 km h from a dead stop on a gradual slope If the walk away braking function remains engaged for two seconds or more a warning buzzer will sound to alert the driver that motor braking has been activated A WARNING e Walk away braking will not limit vehicle speed to 1 mph 1 6 km h on steep grades Do not operate vehicle on slopes exceeding 20 grades Motor Braking This feature helps to control vehicle downhill speed When traveling downhill motor braking engages to maintain speeds proportional to the accelerator pedal position For example when the accelerator is fully depressed motor braking holds the vehicle at the programmed top speed When the accelerator pedal is fully released motor braking slows the vehicle to a complete stop 77 Figure 6 Accelerator and Brake Pedals Villager LSV Owner s Manual Page 19 Controls and Indicators BRAKE PEDAL The brake pedal is the large pedal on the left with the word STOP molded into it Figure 6 To slow or stop the vehicle press the brake p
62. r federal regulations SUBSEQUENT OWNER REGISTRATION In the event an LSV vehicle is bought as a used vehicle we strongly urge the new owner to register the vehicle with Club Car This will enable us to contact you if the need arises Please send your name address and serial number s of the vehicle s to Club Car LLC P O Box 204658 Augusta Georgia 30917 4658 Attention Vehicle Registration Villager LSV Owner s Manual Page 43 Vehicle Specifications VEHICLE SPECIFICATIONS SPECIFICATIONS VILLAGER 2 2 VILLAGER 2 POWER SOURCE Drive motor Direct drive 48 volts DC shunt wound 5 0 hp Transaxle Double reduction helical gear with 10 3 1 direct drive axle Electrical system 48 volts DC reduced speed reverse Batteries High capacity deep cycle Charger Automatic computer controlled 48 volt DC 17 amp UL and CSA listed STEERING SUSPENSION BRAKES Steering Self adjusting rack and pinion Front Suspension Front mono leaf spring with dual hydraulic shocks Rear Suspension Leaf spring with dual hydraulic shocks Brakes Mechanical brake cable system to manually adjusted drum brakes on all four wheels Park brake is released when brake pedal is pressed BODY CHASSIS Frame chassis Twin Beam welded aluminum Rear body Armor Flex ArmorFlex Front body ABS Front body finish Automotive grade paint Tires Standard DOT rated 215 60 R8 Alloy Option DOT rated 205 50 R10 Radial DIMENSIONS WEIGHT 101 in 254
63. rs 3 The hold down straps should be tight enough so batteries do not move while the vehicle is in motion but not so tight as to crack or buckle the battery case Tighten hold down retaining nuts to 55 in lb 6 2 N m The terminal Page 36 Villager LSV Owner s Manual Batteries connections should be clean and tight and any worn insulation or frayed wires should be replaced Tighten battery terminals to proper torque See Connecting the Batteries Electric Vehicles on page 13 After use the batteries should be placed on charge The batteries should never be left discharged any longer than absolutely necessary do not leave batteries discharged overnight BATTERY CARE VEHICLES EQUIPPED WITH THE SINGLE POINT WATERING SYSTEM To keep batteries in good working condition 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 1 cup 237 mL baking soda per gallon 3 8 L of water Rinse solution off of the batteries Do not allow this solution to enter the battery Be sure terminals are tight Let the terminals dry and then coat with Battery Terminal Protector Spray CC P N 1014305 See following NOTE NOTE Dispose of waste water 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 batte
64. ry case Tighten hold down retaining nuts to 55 in lb 6 2 N m The terminal connections should be clean and tight and any worn insulation or frayed wires should be replaced Tighten battery terminals to proper torque See Connecting the Batteries Electric Vehicles on page 13 See following WARNING 4 WARNING e If battery wire terminals are damaged or corroded replace or clean them as necessary Failure to do so may cause them to overheat during operation and could result in fire property damage or personal injury After use charge the batteries The batteries should never be left discharged any longer than absolutely necessary do not leave discharged overnight Water the batteries monthly or according to the watering interval See Establishing the Watering Interval for New Vehicles on page 37 See Watering Batteries with the SPWS on page 40 CAUTION e The watering interval must adequately maintain the electrolyte level above the top of the plates See Figure 14 e Water the batteries only AFTER charging Establishing the Watering Interval for New Vehicles If you do not already have a battery watering interval for your vehicles manually check the battery water level weekly to establish the correct watering interval Thereafter water batteries according to the established interval During periods of heavy use add additional watering as required Single Point Watering System Maintenance 1 For vehicles newly equ
65. s received a sharp blow was dropped or otherwise damaged in any way Do not push objects of any kind into the charger through cabinet slots They may touch dangerous voltage points or cause an electrical short circuit that could result in fire or electrical shock Do not use a charger if The plug is too loose or does not make a good connection The plug and receptacle feel hotter than normal during charge The plug pins or contacts are bent or corroded The plug receptacle or cords are cut worn have any exposed wires or are damaged in any way WARNING CONTINUED ON NEXT PAGE Page 38 Villager LSV Owner s Manual Battery Charger A WARNING Using a charger with any of the above symptoms could result in fire property damage personal injury or death Do not block or cover the charger ventilation slots The slots provide ventilation and prevent the charger from overheating e Do not allow clothing blankets or other material to cover the charger e Do not allow the charger to operate for more than 30 minutes at 19 or more amperes e Install surge arrestors on incoming AC power lines Surge arrestors will help protect electrical components in the charger and on the vehicle from all but direct or close lightning strikes NOTE Because the vehicle s onboard computer OBC has a storage charge feature that automatically checks and recharges the batteries as necessary every 15 days the charger can remain plugged
66. sed on this application Pressing the adjust button one time from the fuel function screen will return to the main screen The speedometer can display average speed max speed and riding time To access the average speed screen from the main screen press the select button one time The digital speed reading and the bar graph will indicate the average speed since the last reset of the Trip B meter as denoted by AVE above the speed Also on this screen the 5 digit seven segment display will indicate riding time since the Trip B meter was last reset When the riding time is displayed as 00 00 the units are 00 hours and 00 minutes When the riding time is displayed as 00 00 the units are 00 minutes and 00 seconds The average speed and riding time may be reset by pressing the select button for 3 seconds from the average speed screen NOTE Resetting the average speed and riding time also resets the Trip B meter function To access the max speed screen press the select button one time from the average speed screen The maximum speed achieved since the last reset will be displayed as denoted by MAX above the speed To reset the max speed press the select button for 3 seconds from the max speed screen To return to the main screen press the select button one time from the max speed screen To check the factory settings for proper speed indication for factory installed tires simultaneously press the select and adjust buttons for 3 seconds The large 3 dig
67. sive gases Do not smoke Keep sparks and flames away from the vehicle and service area Ventilate when charging or operating vehicle in an enclosed area Wear a full face shield and rubber gloves when working on or near batteries e The vehicle will not provide protection from lightning flying objects or other storm related hazards If caught in a storm while driving a Club Car vehicle exit the vehicle and seek shelter in accordance with applicable safety guidelines for your location Villager LSV Owner s Manual Page 11 General Warnings 4 WARNING Follow the procedures exactly as stated in this manual and heed all DANGER WARNING and CAUTION statements in this manual as well as those on the vehicle and battery charger The driver must possess a valid unrestricted drivers license issued by the State in which the vehicle will be operated The driver and passenger must be restrained at all times with the seat belts provided to help prevent injury in the event of sudden braking or collision Do not allow people to ride in any part of the vehicle that is not equipped with a seat and a seat belt Do not allow a third person to sit in the middle of the seat or let a passenger hold a child in his or her lap while the vehicle is moving Do not leave children unattended on vehicle The vehicle is not designed to meet child seat compatibility requirements Children requiring a child safety seat must not ride on the vehicle Comply with
68. state and local laws pertaining to child safety Prior to leaving the vehicle unattended or servicing the vehicle set the park brake place the Forward Reverse handle or switch in the NEUTRAL position turn the key switch to the OFF position and remove the key Chock the wheels when servicing the vehicle Improper use of the vehicle or failure to properly maintain it could result in decreased vehicle performance severe personal injury or death Any modification or change to the vehicle that affects the stability or handling of the vehicle or increases maximum vehicle speed beyond factory specifications could result in severe personal injury or death Check the vehicle for proper location of all vehicle safety and operation decals and make sure they are in place and are easy to read For vehicles with cargo beds remove all cargo before raising the bed or servicing the vehicle If the vehicle is equipped with a prop rod ensure that it is securely engaged while bed is raised Do not close bed until all persons are clear of cargo bed area Keep hands clear of all crush areas Do not drop cargo bed lower gently and keep entire body clear Failure to heed this warning could result in severe personal injury or death Only trained technicians should service or repair the vehicle or battery charger Anyone doing even simple repairs or service should have knowledge and experience in electrical and mechanical repair The appropriate instructions an
69. stem SPWS Az AS A SN Susy Eco AD DA 70 71 Figure 17 Dust Cap Figure 18 Connecting Hose end Assembly to Battery Fill Connector 2 The red flow indicator balls should swirl indicating that the batteries are being filled See following CAUTION CAUTION e If at any time water overflows from the batteries immediately stop the refill process disconnect the pressure regulator from the battery fill coupling and call for service 3 When the red flow indicator balls stop moving immediately press the grey button to disconnect the regulator from the battery fill coupling 9 and squeeze the dust cover 10 to lightly secure it to the male connector of the battery fill coupling Figure 17 Place the battery fill coupling into the space between the battery bucket and the car body Leaving the fill coupling on top of the battery bank or tucked between the batteries and the battery bucket can result in coupling damage 5 Turn the water faucet off when finished filling the vehicle s Page 42 Villager LSV Owner s Manual Cleaning the Vehicle CLEANING THE VEHICLE The Villager Low Speed Vehicle is equipped with an ABS front body and an ArmorFlex rear body Use only commercially available automotive cleaners with a sponge or soft cloth for normal cleaning A garden hose at normal residential water pressure is adequate To remove oxidation or discoloration from aluminum use a commercially available aluminum cleaner paste an
70. surfaces or rough terrain Do not drive while under the influence of alcohol drugs or medications e Use brakes to reduce speed when coasting downhill e Avoid roads with regular traffic even if the speed limit is low e Avoid operating the vehicle at night or in adverse weather conditions because your vehicle may be difficult for others to see If the vehicle must be operated at night use headlights and taillights e Do not drive the vehicle under tree limbs bridges tunnels or other objects that are less than 80 inches from the ground e This vehicle is not intended to be used where risk of falling objects exists If your vehicle will be used In such an environment contact your local dealer No one should drive the vehicle without first being instructed in the proper operation and use of the vehicle s controls An experienced operator should accompany each first time driver on a test drive before allowing them to operate the vehicle alone To ensure safe operation of the vehicle follow exactly and in order all of the following procedures Read and understand all instructions prior to driving the vehicle STARTING THE VEHICLE 1 Study and understand controls 2 Make sure load is secure 3 Make sure everyone is seated restrained in seat belts and holding onto hand holds Driver should have both hands on the steering wheel 4 Read safety and information decals located on the steering wheel the dash panel and above the
71. t attempt to jump or otherwise exit the vehicle Remain seated with seat belt fastened and with arms and legs inside the vehicle After inserting the tab make sure the tab and buckle are locked and that the belt is not twisted Make sure the shoulder belt is positioned across the center of the shoulder The belt should be kept away from the neck but not falling off the shoulder Failure to do so could reduce the amount of protection and increase the chance of injury WARNING CONTINUED ON NEXT PAGE Villager LSV Owner s Manual Page 23 Seat Belts 4 WARNING 194A 194 Figure 11 Retractable Seat Belt Figure 12 Non Retractable Seat Belt Loose fitting seat belts could increase the chance of injury due to sliding under the belt if sudden braking should occur Keep the seat belt snug and positioned as low on the hip bone as possible Use a single seat belt for one person at a time Do not use a single seat belt for two or more people this includes children No more than two persons per bench seat at one time Do not allow people to ride in any part of the vehicle that is not equipped with a seat and a seat belt Do not allow a passenger to hold a child in his or her lap while the vehicle is moving Be careful not to damage the seat belt webbing or hardware Inspect the seat belt system periodically Check for cuts fraying and loose parts Damaged parts should be replaced immediately Do not disassemble or modify the sys
72. t falling off the shoulder The retractor will lock the belt during a sudden stop It also may lock if the occupant leans forward too quickly A slow easy motion will allow the belt to extend and the occupant can move freely If the seat belt cannot be pulled out of the retractor firmly pull the belt and release it It should then pull smoothly out of the retractor To release the seat belt press the buckle release button 1 and allow the belt to retract Figure 11 If the belt does not retract smoothly pull it out and check for kinks or twists Then make sure it remains free of twists as it retracts Rear facing seats To secure the non retractable seat belt sit up straight and well back in the seat Pull the seat belt 1 over your hips and insert the tab into the buckle A click will be heard when the tab locks into the buckle Position the seat belt as low as possible on the hips not on the waist After inserting the tab make sure the tab and buckle are locked and that the belt is not twisted The seat belt should be snug but comfortable Figure 12 To remove the slack in the seat belt pull on the inner seat belt loop in order to tighten the seat belt To release the seat belt press the buckle release button A WARNING The driver and all passengers must be restrained at all times with the seat belts provided to help prevent injury in the event of sudden braking collision or roll over In the event of a roll over do no
73. t the andarina chicos vhiles li higher scores Turn key but not greater than 25 mph Global Warming Score Smog Score Shall only be operated in the manner and locations permitted by law 10 e Shall not be operated on a public highway with a speed limit in excess Cc al fully Vehicle will start moving whe a ed of 35 mph provided the maximum posted speed limit for lawful frigo Cuan ator pedal to increase speed Tostoj celerator pedal and press brake pedal operation in Maryland is 30 mph and the limit for Idaho is 25 mph a ahaa May be a hazard on the roadways if it impedes traffic Using atra uct may prov econ os unto que May subject the driver to citations for impeding traffic Vohicio erstestons aro a pulmary contar to UNINTENDED VEHICLE MOVEMENT MAY CAUSE SEVERE INJURY OR DEATH May not be equipped with such safety features as bumpers a padded After stopping firmly set par nd place Forward Reverse switch in NEUTRAL position dashboard visors or a tamper resistant odometer 103537001 Turn key OF F and remove key when not in use 103757901 AM 5J5LD22 Bx2Ax00000x COLLISION ROLLOVER OR FALLING OFF MAY CAUSE SERIOUS INJURY OR DEATH BEFORE USING VEHICLE READ OPERATING INSTRUCTIONS Occupants must fasten seat belts and remain seated while moving Use CAUTION when operating vehicle in the presence of higher speed vehicles in congested areas or on unimproved surfaces
74. tem Keep seat belts clean and dry If cleaning is necessary use a mild soap and lukewarm water solution Do not use bleach dye or abrasive cleaners as they may severely weaken the seat belts Do not insert coins clip etc in the buckle as this may prevent the tab from locking into the buckle properly If the seat belt does not function normally contact your dealer distributor or trained technician immediately Do not occupy the seat until the seat belt is repaired Page 24 Villager LSV Owner s Manual Transporting Children TRANSPORTING CHILDREN 4 WARNING e The vehicle is not designed to meet child safety seat compatibility requirements Children requiring a child safety seat or that could benefit from the protection of one must not ride on the vehicle Comply with state and local laws pertaining to child safety e Do not leave children unattended on vehicle e Do not allow a passenger to hold a child on his or her lap while the vehicle is moving PRE OPERATION AND DAILY SAFETY CHECKLIST Each Club Car vehicle has been carefully inspected and adjusted at the factory however upon receiving your new vehicle s you should become familiar with its controls indicators and operation Carefully inspect each vehicle to ensure that it is in proper working condition before accepting delivery Use the following checklist as a guide to inspect the vehicle This checklist should be used daily to ensure that the vehicle is in proper wor
75. the adjust button on the right The main screen for the speedometer shows the speed digitally large 3 digit seven segment display centrally located with the bar graph around the periphery and the odometer displayed below the speed small 5 digit seven segment display denoted by ODO on the left side of the numbers The speedometer has three range settings 160km h 260km h and 160MPH The range setting may be indexed to the next setting by pressing and holding the adjust button for 3 seconds from the main screen The speedometer also has a Trip A and Trip B meter function for recording user selectable distances To access the Trip A function press the adjust button one time from main screen The small 5 digit seven segment display will now indicate the distance travelled since the last Trip A reset and is denoted by TRIP A on the left side of the numbers To reset the Trip A meter press the adjust button for 3 seconds from the Trip A function screen To access the Trip B function press the adjust button one time from the Trip A screen The small 5 digit seven segment display will now indicate the distance travelled since the last Trip B reset and is denoted by TRIP B on the left side of the numbers To reset the Trip B meter press the adjust button for 3 seconds from the Trip B function screen Pressing the adjust button one time from the Trip B function screen will index the display to the fuel function screen The fuel function screen is not u
76. ther side to turn the lights off BRAKE LIGHTS The brake lights will illuminate when the brake pedal or the park brake is pressed See following NOTE NOTE When the key switch is in the OFF position the brake lights are disabled TURN SIGNALS The turn signal switch 1 is located on the steering column Figure 10 Move the handle up to indicate a right hand turn Move the handle down to indicate a left hand turn Return the handle to the center position after completing a turn Villager LSV Owner s Manual Page 21 Seat Belts HAZARD LIGHTS The hazard light switch 2 is located just below the turn signal switch Figure 10 To activate the hazard lights make sure that the turn signal switch is in the center off position and pull the switch marked hazard until it is locked in place by the turn signal switch To deactivate the hazard lights move the turn signal switch in either direction and return it to the center position HORN The horn button 3 is located on the end of the turn signal lever Figure 10 Press the button to activate the horn SPEEDOMETER The speedometer 4 is located on the steering column Figure 10 The speedometer provides information on vehicle speed odometer and trip odometer The Koso Speedometer has two buttons for selecting and or adjusting the features and functions available The buttons are located on the lower front portion of the speedometer with the select button on the left and
77. tiso tal o ae a a e aa aeaa eaa aaaea a a e a i aeaa habias tods 44 WAIT AMOS Corr A TEETER 46 Villager LSV Owner s Manual Page 3 Practice Safety PRACTICE SAFETY N WARNING Rotating Parts Safety signs like you see above may at first seem shocking but their impact is mild compared with the reality of severe personal injury Your safety and satisfaction are of the utmost importance to us That is why before operating the vehicle we urge you to review the information 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 to understand the language of safety It is a language that can save your life 4 WARNING e The LSV electric vehicle is equipped to operate at a top speed of 25 mph 40 km h and is intended for use as a low speed vehicle e This vehicle offers much less crash protection than a regular car van or truck This results in a higher risk of injury or death in collisions even at low speeds The higher the speed of traffic around you the higher the risk of injury To reduce risks Do not operate this vehicle in a manner that impedes traffic Whenever possible stay on roads and lanes limited to low speed vehicles Wear your seat belt at all times Avoid operating at night because this vehicle may be hard for others to see Never operate under the inf
78. ty you must present the vehicle or defective component to an authorized CLUB CAR LSV Dealer Please contact a Club Car Warranty Department Representative at 800 227 0739 to locate the nearest authorized CLUB CAR LSV Dealer in your area DISCLAIMER THIS LIMITED WARRANTY IS EXCLUSIVE CLUB CAR MAKES NO OTHER WARRANTY OF ANY KIND EXPRESSED OR IMPLIED ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS OR TIME LIMITS STATED IN THIS WARRANTY ARE HEREBY DISCLAIMED BY CLUB CAR AND EXCLUDED FROM THIS WARRANTY THE PURCHASER AND CLUB CAR EXPRESSLY AGREE THAT THE REMEDY OF THE REPLACEMENT OR REPAIR OF THE DEFECTIVE VEHICLE OR COMPONENT THEREOF IS THE SOLE REMEDY OF THE PURCHASER CLUB CAR MAKES NO OTHER REPRESENTATION OR WARRANTY OF ANY KIND AND NO REPRESENTATIVE EMPLOYEE OR DEALER OF CLUB CAR HAS THE AUTHORITY TO MAKE OR IMPLY ANY REPRESENTATION PROMISE OR AGREEMENT WHICH IN ANY WAY VARIES THE TERMS OF THIS WARRANTY In the event that another pre printed warranty document and or certificate offered by or through Club Car at the time of sale of this vehicle each an Additional Warranty Document is deemed to conflict with the limitations or exclusions contained herein the limitations and exclusions contained herein shall continue to apply with respect to both this limited warranty statement and to the maximum extent permitted by law to each Additional Warranty Document NO CONSEQUENTIAL
79. wable minerals solids and contaminates in parts per million and their impact on battery performance Your local water company should be able to perform testing and compare their results to the chart If using tap water Club Car s Service Parts Department offers two different deionzier systems one for vehicles equipped with the Single Point Water System SPWS CC P N AM1240701 and the other for vehicles without SPWS CC P N AM10974 ALLOWABLE CONTENT PARTS IMPURITY PER MILLION EFFECTS OF IMPURITY Organic and volatile matter 50 0 Corrosion of positive plates Antimon Self discharge reduces life lower i 5 on charge voltage Loss of capacity in plates greater loss Chloride sde in positive plates Increased self discharge lower on charge voltage Increased self discharge lower on charge voltage a o a o None allowed Intense lowering of on charge voltage 10 0 Increased sulfation of negative plate wo o AJN a a ol olo o o a BATTERY CARE VEHICLES WITHOUT THE SINGLE POINT WATERING SYSTEM To keep batteries in good working condition follow this maintenance program on a regular basis Proper battery maintenance is critical not only for good performance but also for safe operation See following WARNING Villager LSV Owner s Manual Page 35 Batteries A WARNING Ensure battery connections are clean and properly tightened e Use only 4 gauge AWG wires with low resistance terminals to repl
80. water is boiled the steam is collected and then condensed back into water This process creates a finished product free of minerals having left all the impurities in the original water sample Club Car along with our battery manufacturers highly recommends that distilled water be used in electric vehicle batteries Page 34 Villager LSV Owner s Manual Batteries Deionized water is the purest form of water but it is also the most expensive Deionization removes all ionizable particles organic and inorganic from water through ion exchange Positively and negatively charged ions are removed from the water and replaced with H and OH ions When these two ions are combined they form H20 or purified water Reverse osmosis is a method of removing solids from water by forcing it through a membrane The membrane rejects all solids while allowing purified water to pass through The choice of membrane determines the amount of impurities that the water may contain Water from municipal supplies ponds and wells usually contain detrimental levels of dissolved minerals and chemicals If using tap water it is important to use an in line deionizer to remove impurities that can damage batteries and significantly reduce battery life If tap water is used without a deionizer regular water analyses must be conducted to check for impurities because water companies commonly revise their additives on a periodic basis The following chart lists the maximum allo
81. wheel e General Listen for any unusual noises such as squeaks or rattles Check the vehicle ride and performance Have a Club Car distributor dealer or a trained technician investigate anything unusual Accelerator With the key switch in the ON position and the Forward Reverse switch in the FORWARD position as the accelerator pedal is pressed the motor should start and the vehicle should accelerate smoothly to full speed Club Car vehicles operate at reduced speed in reverse When the pedal is released it should return to the original position and the motor should go into motor braking mode See Motor Braking below e Walk Away Braking With the vehicle parked on level ground and the park brake disengaged place the Tow Run switch in the RUN position and attempt to push the vehicle Motor braking should engage and cause resistance to rolling moving at no more than 1 to 3 mph 1 5 to 4 8 km h with the Forward Reverse switch in any position When walk away braking is engaged the reverse buzzer should emit a distinct pattern of beeps See following WARNING A WARNING e Walk away braking will not limit vehicle speed to 1 mph 1 6 km h on steep grades Do not operate vehicle on slopes exceeding 20 grades Motor Braking Accelerate down an incline with the accelerator pedal fully pressed When the vehicle reaches maximum programmed speed motor braking should engage and limit the vehicle to its maximum programmed speed On very steep

Villager LSV OM-103700406 1009D1010C

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