Columbia ParCar P4E-SE-48A User manual

SERVICE MANUAL
Models
Eagle Electric Golf Cars
Models
P4E-LE-48A & P4E-LE-48S
P4E-SE-48A & P4E-SE-48S
© December 2007
Find replacement parts for your cart faster at CartPros.com

2007 Eagle Electric Golf Car Service Manual © December 2007i
GENERAL
This service manual has been prepared with two purposes. First,
it will introduce the trained maintenance professional to the latest
field tested and factory approved major repair methods. Secondly,
it will acquaint the reader with the construction of the Columbia
ParCar vehicles and assist him/her in performing basic mainte-
nance and repair. We sincerely believe that this manual will make
the association with Columbia ParCar vehicles a more pleasant
and profitable experience.
In addition to the information given in this manual, Service Bul-
letins are issued to Columbia ParCar dealers, which cover interim
engineering changes and supplementary information. Service Bul-
letins should be consulted for complete information on the models
covered by this manual.
To ensure the safety of those servicing our vehicles and to protect
the vehicles from possible damage resulting from improper ser-
vice or maintenance, the procedures in this manual should always
be followed exactly as specified. Execution of the procedures and
troubleshooting tips as outlined will ensure the best possible ser-
vice from the vehicle(s). To reduce the chance of personal injury
and/or property damage, carefully observe the DANGER, WARN-
ING, CAUTION & NOTICE recommendations throughout this
manual. See Section 1-Safety for additional details.
PREPARATION FOR SERVICE
Proper preparation is very important for efficient service work. A
clean work area at the start of each job will allow you to perform
the repair as easily and quickly as possible, and reduce the inci-
dence of misplaced tools and parts. Columbia ParCar vehicles
that are excessively dirty should be cleaned before work begins.
Cleaning will occasionally uncover trouble sources. Tools, instru-
ments and parts needed for the job should be gathered before
work is started. Interrupting a job to locate tools or parts is a
needless delay. Special tools required for a job are listed at the
beginning of each section.
MODEL IDENTIFICATION
Always give the vehicle identification number (VIN) when order-
ing parts or making inquiries about the vehicle. Use of the full and
complete vehicle identification number will ensure that the dealer
or service provider is supplying you with the correct parts for the
vehicle. See Section 2-General Information for VIN location and
additional information.
USE GENUINE REPLACEMENT PARTS
WARNING
When replacement parts are required, use only genuine
Columbia ParCar parts or parts with equivalent characteris-
tics including type, strength and material. Failure to do so
could result in product malfunction and possible injury to
the operator and/or passenger.
To ensure a satisfactory and lasting repair job, follow the service
manual instructions carefully and use only genuine Columbia
ParCar vehicle replacement parts. This is the insurance that the
parts you are using will fit right, operate properly and last longer.
When you use genuine Columbia ParCar vehicle parts, you use
the best.
PRODUCT REFERENCES
When reference is made in this manual to a specific brand name
product, tool or instrument, an equivalent product, tool or instru-
ment may be used in place of the one mentioned.
Foreword
Find replacement parts for your cart faster at CartPros.com

2007 Eagle Electric Golf Car Service Manual © December 2007ii
Table of Contents
SECTION 5 - ACCELERATOR AND BRAKES
Accelerator Pedal ...................................................................5-2
Mechanical Brake System......................................................5-2
General................................................................................ 5-2
Periodic Brake Inspection.................................................... 5-2
Annual Brake Inspection ..................................................... 5-2
Mechanical Rear Drum Brake ............................................. 5-3
Brake Cable Replacement .................................................. 5-5
Mechanical Brake Adjustments ........................................... 5-5
Hydraulic Brake System .........................................................5-6
General................................................................................ 5-6
Periodic Brake Inspection.................................................... 5-6
Annual Brake Inspection ..................................................... 5-6
Hydraulic Rear Drum Brake ................................................ 5-6
Hydraulic Master Cylinder ................................................... 5-9
Hydraulic Front Disc Brake ............................................... 5-10
Hydraulic Brake Adjustments ............................................ 5-12
SECTION 6 - FRONT WHEELS, STEERING
& FRONT SUSPENSION
General................................................................................... 6-2
Specifications ......................................................................... 6-2
Front Wheels and Hubs.......................................................... 6-2
Removing Front Wheels and Hubs ..................................... 6-2
Inspecting/Replacing Wheel Hub Bearings......................... 6-2
Installing Front Wheel Hubs and Wheels ............................ 6-2
Tires........................................................................................ 6-4
General................................................................................ 6-4
Removing Tire ..................................................................... 6-4
Installing Tire ....................................................................... 6-4
Steering Wheel....................................................................... 6-5
Removing Steering Wheel................................................... 6-5
Installing Steering Wheel..................................................... 6-5
Rack and Pinion Steering Assembly....................................... 6-5
Removing Rack and Pinion Steering Assembly .................. 6-5
Disassembling Rack and Pinion Steering Assembly........... 6-5
Assembling Rack and Pinion Steering Assembly................ 6-6
Installing Rack and Pinion Steering Assembly.................... 6-6
Front Suspension System ...................................................... 6-6
Replacing Shock Absorbers ................................................ 6-6
Replacing Front Leaf Spring................................................ 6-6
Disassembling Kingpin, Steering Arm and A-Arm ............... 6-6
Assembling Kingpin, Steering Arm and A-Arm .................... 6-7
Steering and Front suspension Adjustments.......................... 6-7
Camber Adjustment............................................................. 6-7
SECTION 1 - SAFETY
Overview................................................................................. 1-2
Safety Information .................................................................. 1-2
Safety Preparations................................................................ 1-3
Icons in Procedures................................................................ 1-4
Decals..................................................................................... 1-4
SECTION 2 - GENERAL INFORMATION
Model information................................................................... 2-2
Vehicle Model Information................................................... 2-2
Vehicle Identification Number (VIN) Charts......................... 2-2
Safety Committee................................................................... 2-2
Vehicle Specifications............................................................. 2-3
Controls and Operation .......................................................... 2-4
Location of Controls ............................................................ 2-4
Operation............................................................................. 2-4
Pre-operation Inspections....................................................... 2-5
Pre-operation Check List........................................................ 2-5
SECTION 3 - MAINTENANCE
Periodic Maintenance............................................................. 3-2
Batteries ................................................................................. 3-5
Chassis Lubrication ................................................................ 3-5
Wheel Hubs......................................................................... 3-5
Brake Pedal......................................................................... 3-5
Rear Axle................................................................................ 3-5
Chassis Cleaning.................................................................... 3-5
Seat Cleaning......................................................................... 3-5
Lifting instructions................................................................... 3-6
Tools Required .................................................................... 3-6
Hoist Lifts............................................................................. 3-6
Floor Jack Procedure .......................................................... 3-6
Jack Stands......................................................................... 3-6
Vehicle Storage ...................................................................... 3-7
Returning Vehicle to Service .................................................. 3-7
Towing the Vehicle.................................................................. 3-7
Transporting the Vehicle......................................................... 3-7
Torques and Metric Conversion Factors................................. 3-8
SECTION 4 - TROUBLESHOOTING
Pre-Troubleshooting Steps..................................................... 4-2
Battery Testing........................................................................ 4-3
Troubleshooting Specific Complaints ..................................... 4-4
ACEPlus Sevcon Controller Power System ........................... 4-8
Smartdrive Sevcon Controller Power System ...................... 4-12
Speed Switch (Pot Box) Testing ........................................... 4-14
Component Troubleshooting ................................................ 4-14
Find replacement parts for your cart faster at CartPros.com

2007 Eagle Electric Golf Car Service Manual © December 2007iii
Table of Contents
Toe In Adjustment................................................................ 6-7
SECTION 7 - REAR WHEELS, REAR SUSPENSION
& AXLE ASSEMBLY
Rear Wheels........................................................................... 7-2
Removing Rear Wheels ...................................................... 7-2
Rear Axle Wheel Bearings .................................................. 7-2
Installing Rear Wheels ........................................................ 7-2
Tires........................................................................................ 7-2
Rear Suspension.................................................................... 7-2
Replacing Rear Shock Absorbers ....................................... 7-2
Replacing Rear Springs ...................................................... 7-2
Replacing Rear Frame Bushings ........................................ 7-3
Rear Axle Assembly................................................................ 7-3
Removing Rear Axle............................................................ 7-3
Disassembling Rear Axle .................................................... 7-6
Assembling Rear Axle ......................................................... 7-9
Installing Rear Axle.............................................................7-11
Rear Axle Differential Oil ...................................................... 7-12
Changing Differential Oil ................................................... 7-12
SECTION 8 - BODY AND CHASSIS
Front Body.............................................................................. 8-2
Replacing Front Headlight Bulb.............................................. 8-2
Replacing Front Turn Signal Bulb........................................... 8-2
Front Bumper.......................................................................... 8-3
Back Rests and Frame........................................................... 8-3
Seat Cushion and Handrails................................................... 8-4
Center Body............................................................................ 8-4
Bag Rack................................................................................ 8-5
Tail Lights and Rear Turn signals ........................................... 8-5
Rear Body............................................................................... 8-6
Rear Bumper .......................................................................... 8-6
Console Controls.................................................................... 8-6
Replacing Power On Off Key Switch................................... 8-6
Replacing Directional Key switch ........................................ 8-7
Replacing Head Light Switch .............................................. 8-7
Replacing Battery Discharge Indicator (BDI)....................... 8-7
Steering Wheel....................................................................... 8-7
Horn........................................................................................ 8-8
Turn Signal / Emergency Flasher Control .............................. 8-8
SECTION 9 - BATTERIES AND BATTERY CHARGER
Safety ..................................................................................... 9-2
General Information................................................................ 9-3
Battery Inspection................................................................... 9-3
Battery Cleaning..................................................................... 9-3
Battery Service (Water) .......................................................... 9-4
Battery Charging..................................................................... 9-5
Delta-Q Charger Operation .................................................... 9-8
REd Light Charger Error Codes ............................................. 9-8
Charging Procedure ............................................................... 9-9
Special Charging Procedure
for Excessively Discharged Batteries ................................. 9-10
Testing Batteries................................................................... 9-10
Storing Batteries................................................................... 9-12
Replacing Batteries .............................................................. 9-12
Battery Charger ................................................................... 9-12
SECTION 10 - TRACTION DRIVE SYSTEM
Traction motor ...................................................................... 10-2
Maintenance...................................................................... 10-2
External Motor Inspection.................................................. 10-2
Internal Motor Inspection................................................... 10-2
Traction Motor Removal .................................................... 10-2
Traction Motor Disassembly.............................................. 10-3
Armature Inspection .......................................................... 10-3
Armature Testing ............................................................... 10-4
Brushes ............................................................................. 10-4
Brush Springs.................................................................... 10-4
Bearing.............................................................................. 10-6
Frame and Field Coils ....................................................... 10-6
Field Coil Maintenance ..................................................... 10-6
Inspection ......................................................................... 10-6
Traction Motor Reassembly .............................................. 10-6
Traction Motor Installation ................................................. 10-7
Controller.............................................................................. 10-8
Smartdrive Traction Motor System .................................... 10-8
ACEplus Traction Motor System ....................................... 10-8
Controller Testing ............................................................. 10-8
Removing the Controller ................................................... 10-8
Installing the Controller...................................................... 10-9
Contactor/Solenoid............................................................ 10-9
Removing the Contactor.................................................... 10-9
Installing the Contactor ..................................................... 10-9
Find replacement parts for your cart faster at CartPros.com

2007 Eagle Electric Golf Car Service Manual © December 2007iv
THIS PAGE INTENTIONALLY LEFT BLANK.
Find replacement parts for your cart faster at CartPros.com