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
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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
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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
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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
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2007 Eagle Electric Golf Car Service Manual © December 2007iv
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2007 Eagle Electric Golf Car Service Manual © December 20071-1
Section 1 - Safety
OVERVIEW ........................................................................................... 1-2
SAFETY INFORMATION ...................................................................... 1-2
SAFETY PREPARATIONS ................................................................... 1-3
ICONS IN PROCEDURES .................................................................... 1-4
DECALS................................................................................................ 1-4
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2007 Eagle Electric Golf Car Service Manual © December 20071-2
Section 1 - Safety
OVERVIEW
Statements in this manual preceded by the words DANGER,
WARNING, CAUTION or NOTICE and words printed in bold
face are very important. We recommend you take special notice
of these items.
It is important to note that some warnings against the use of spe-
cific service methods, which could damage the vehicle or render
it unsafe, are stated in this service manual. However, please re-
member that these warnings are not all inclusive. Since Columbia
ParCar Corporation could not possibly know, evaluate and advise
servicing personnel of all possible ways in which service might be
done or of the possible hazardous consequences of each way, we
have not undertaken any such broad evaluation.
Accordingly, anyone who uses a service procedure or tool which
is not recommended by Columbia ParCar must first thoroughly
satisfy him/herself that neither their nor the operator’s safety will
be jeopardized by the service methods selected.
DANGER
Danger indicates a hazardous situation which, if not avoided,
WILL result in death or serious injury to the operator or by-
standers.
WARNING
Warning indicates a hazardous situation which, if not avoid-
ed, COULD result in death or serious injury to the operator
or bystanders.
CAUTION
Caution indicates a hazardous situation which, if not avoid-
ed, MAY result in moderate or minor injury to the operator or
bystanders.
NOTICE
Notices are messages not related to personal injury. They
will provide key information to prevent property damage
and to ensure procedures are more easily understood or
implemented.
SAFETY INFORMATION
It is Columbia ParCar’s specific recommendation that the fol-
lowing safety information must be observed at all times. Not all
are repeated throughout this manual, but the recommendations
included must be observed whenever these subjects (indoor
vehicle operation hazards are encountered.
DANGER
Any modifications or changes to the vehicle that affect the
stability or increases vehicle speed beyond factory specifi-
cations could result in severe personal injury or death.
Always, remove keys and disconnect the batteries before
servicing or repairing your vehicle. See Section 8-Batteries,
for specific details.
All batteries used in electric vehicles
can explode! Always wear full face
shield when working on or near bat-
teries. Hydrogen fumes are a natural
byproduct of charging and discharg-
ing and are extremely explosive.
Do not smoke around electric vehicle
batteries. Keep sparks and flames away
from batteries. Battery charging should
only be done in a well-ventilated area. Refer
to Section 9-Batteries for details.
Batteries contain acid which can
cause severe burns. Causes severe
burns. Avoid contact with skin,
eyes, or clothing. Wear full face
shield and rubber gloves when
working on or near batteries.
ANTIDOTES:
- External: Flush with water. Call a physician immediate-
ly.
- Internal: Drink large quantities of milk or water. Follow
with milk of magnesia or vegetable oil.
- Eyes: Flush with water for fifteen minutes. Call a physi-
cian immediately.
When working around batteries, use approved insulated
tools, remove jewelry such as rings, watches, chains, etc.
and place an insulating material such as wood, plastic, rub-
ber, etc. over batteries covering all connections.
If any problems are found during scheduled maintenance or
inspections, Do not operate vehicle until repairs are made.
Failure to make necessary repairs could result in fire, prop-
erty damage, severe personal injury or death.
WARNING
Only trained maintenance professionals should repair or ser-
vice this vehicle. Persons doing even simple repairs or ser-
vice should have working knowledge and experience in gen-
eral electrical and mechanical repair. Follow all procedures
exactly and observe all warnings stated in this manual. Use
caution and common sense.
Proper service and repair is important for safe, reliable op-
eration of all Columbia Industrial/Commercial vehicles. The
service procedures recommended and described in this ser-
vice manual are effective methods for performing service op-
erations. Some of these service operations require the use
of tools specially designed for this purpose. These special
tools should be used when and as recommended.
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2007 Eagle Electric Golf Car Service Manual © December 20071-3
Section 1 - Safety
HOT
HOT! DO NOT attempt to service hot electric
motor or resistors. Failure to observe this
warning could result in severe burns.
CAUTION
Golf car vehicles are designed to transport one (1) operator
and one passenger unless adequate provisions have been
factory installed to accommodate additional passengers.
Never exceed the rated load capacity or vehicle stability, reli-
ability and control will be reduced. See vehicle identification
plate for capacities and gross vehicle weights.
Cautions appear throughout this manual indicating possible
hazards or unsafe practices that may result in minor personal
injury, damage to vehicles or property.
SAFETY PREPARATIONS
Always turn Power key to OFF, Directional
key switch to Neutral, remove Power key,
block tires and disconnect the battery
negative (-) cable before performing any
vehicle service to avoid accidental startup
of vehicle and possible personal injury.
SAFETY FIRST
Use insulated tools when working near batteries or electrical
connections. Use extreme caution to avoid shorting of com-
ponents or wiring.
Moving parts hazard! Watch for inter-
national symbol icons in the margins.
When operating any vehicle in a sta-
tionary position, avoid chains, belts,
and wheels which could snag clothing
or cause severe injury to body parts. A
running vehicle must be worked on
with the greatest care. Use caution and
common sense.
Do not wear loose clothing or jewelry such as rings, watches,
chains, etc. when servicing the vehicle. Failure to do so could
result in personal injury or death.
Working on Columbia ParCar vehicles without following
proper procedures and using proper lifting equipment may
result in vehicle damage or personal injury. See Section 3 -
Lifting Instructions detailed instructions.
Always wear safety glasses or approved eye protection while
servicing vehicle. Wear a full face shield when working with
batteries.
Failure to maintain vehicle properly could result in decreased
vehicle performance, reliability or cause severe personal in-
jury.
Exceeding rated vehicle load capacities could result in pos-
sible severe injury or property damage.
Check the vehicle for proper location and condition of all ve-
hicle safety and operation decals. Refer to pages 1-4 & 1-5
for locations.
The modification of vehicles for use in other than its intended
purpose is not recommended. Any unauthorized modifica-
tion may void your vehicle warranty.
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2007 Eagle Electric Golf Car Service Manual © December 20071-4
Section 1 - Safety
ICONS IN PROCEDURES
Watch out for icons and symbols in procedures. They are there to
help you avoid situations that might expose you to an unneces-
sary hazard or potential injury
DECALS
Safety, Warning and Informational decals should be ordered and
replaced as soon as they are discovered to be illegible or missing.
Refer to Parts Manual or web site for part numbers and ordering
info.
Refer to Figures 1-1 for location of the decal.
1. Use a heat gun or hair dryer to soften up and remove any
damaged sticker.
2. Peel off backing and carefully position and press decal into
place.
Figure 1-1. Warning and Operating Instructions Decal on Console
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2007 Eagle Electric Golf Car Service Manual © December 20072-1
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
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