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 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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2007 Eagle Electric Golf Car Service Manual © December 20072-2
Section 2 - General Information
MODEL INFORMATION
Vehicle Model Information
Model Group Name Use Power
Identifiers Type System
VIN Digits
1-3
P4E-LE P4L Eagle Golf Car Battery
48 Volt
P4E-SE P4S Eagle Golf Car Battery
48 Volt
Vehicle Identification Number (VIN) Charts
Digit 1 - 3 P4L
Model Identifier P4S
Digit 4 A = Series, Resistor
Power System B = Series, Solid State
C = Separately Excited Plug, Smartdrive
D = Separately Excited Plug,
High Power, Smartdrive
E = Separately Excited Regenerative, ACEplus
F = Separately Excited Regenerative with
encoder, ACEplus
Digit 5 1 = 12V
System Voltage 2 = 24V
3 = 36V
4 = 48V (8 - 6V)
B = 48V (4-12V)
D = Dual 48V (8-6V / 8-6V)
G = 48V GEL (8-6V)
Digit 6 (-) = Standard
Standard or (#) = Special
Special Product
Digit 7 3 = 300 Amp
Controller 4 = 400 Amp
Amperage 5 = 500 Amp
Digit 8 Z = H12: Rear mechanical
Axle/Brake Y = H12: Rear Hydraulic
System X = H12: Front and Rear Hydraulic
Digit 9 E = 2006
Year Built F = 2007
G = 2008
H = 2009
NOTICE
Always provide the complete VIN when contacting your deal-
er for technical assistance or maintenance and repair parts.
The VIN is printed on a white label, affixed to the frame, under
the dash (Figure 2-1). It is also affixed to the steering wheel
under the steering wheel cover (Figure 2-2).
SAFETY COMMITTEE
If the vehicles are to be operated by renters or company employ-
ees, we recommend that a safety committee be appointed. The
primary concern of this committee should be the safe operation
of the vehicles.
Subjects which must be considered include, but are not limited to,
the following:
• Define where the vehicles should and should not be driven
and utilized.
• Ensure all proper warnings as to driving hazards are properly
displayed and visible.
• Safety signage concerning hills, turns, blind crossings or in-
tersections is highly recommended.
• Enforcement of safe driving and operating rules.
• Provide driver training for first time operators, and review safe
operating recommendations regularly.
• Maintain vehicles in a safe operating condition. Maintain a
schedule for daily, weekly, and monthly vehicle inspections.
Figure 2-1. VIN Location on Under Dash
VIN Label
Figure 2-2. VIN Location on Steering Wheel
VIN Label
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2007 Eagle Electric Golf Car Service Manual © December 20072-3
Section 2 - General Information
• Determine who, when and how pre-operation inspections
should be conducted.
• Enforcement of safe driving and operating rules.
• Define who should and who should not drive the vehicles.
• Decide what to do should an unsafe condition or operating
problem be discovered.
• Enforce that vehicle should not be operated by persons under
the age of 16.These basic rules of operation, combined with
courtesy and common sense, will help make driving your Co-
lumbia ParCar Vehicles a safe and pleasant experience.
VEHICLE SPECIFICATIONS
Columbia ParCar Corporation reserves the right to change spec-
ifications, equipment or designs at any time without notice and
without incurring obligations.
Item Specifications Vehicle
Power Source P4E-LE P4E-SE
48 volt, 15.3 hp @ 1750 rpm √-
48 volt, 17.3 hp @ 1975 rpm √
Drive Direct coupled to oil bath, helical geared, rear axle √√
Programmable, solid state, reduced speed reverse
with diagnostic LED and calibrator interface
12.44:1 helical gear reduction with integral differential √-
10.35.1 helical gear reduction with integral differential - √
Batteries
Deep Cycle
Built in, micro-processor control, fully sealed, anti-drive away
interlock, 110-240 V AC, 50/60 Hz
Directional Console mounted Safety Directional Keyswitch
Control with F (forward), R (reverse) and N (neutral)
Spring applied, auto-adjusting mechanical drum on
rear wheels, foot operated parking brake. Optional rear self-adjusting hydraulic
brake with hand-operated mechanical parking brake. Optional front hyraulic
brakes.
Steering Automotive rack and pinion. √√
18.5” x 8” DOT rated tires on steel wheels √
175/50 R13 (7x20x13) DOT rated radial tires on chrome wheels √
Mig-welded tubular steel, electrostatic powder coated √√
Lifted profile chassis (5.5” ground clearance) - √
Total number of occupants 2/4 2/4
Cargo not to exceed __ lbs, including driver 750 750
For a full list of dimensions and capacities, refer to the vehicle’s Owner’s Manual.
√√
√√
√
√
√
√
√√
Motor
Speed Control
Rear Axle
Charger
Brakes
Tires
Frame
Rated Capacity
48 Volt: 8 - 6 volt, heavy duty, 225 Ah
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2007 Eagle Electric Golf Car Service Manual © December 20072-4
Section 2 - General Information
CONTROLS AND OPERATION
Location of Controls
Figure 2-3 shows the location of the vehicle’s controls.
Operation
NOTICE
Controls should operate smoothly and easily without stick-
ing or requiring undue effort.
1. Set the power key switch to the ON position.
3. Set the directional key switch to the desired direction of travel
(F=Forward, R=Reverse).
4. Depress accelerator with the right foot.
5. To stop the vehicle, release the accelerator pedal and apply
the brake pedal slowly and completely.
WARNING
Be sure safety directional key switch is in desired direction of
travel before depressing accelerator.
Power OFF ON
Key Switch
Directional F-N-R
Key Switch
Horn
Battery Discharge
Indicator (BDI)
Accelerator Pedal
Brake Pedal
Steering Wheel
Head Light
Switch
Directional Key
Switch R-N-F
Emergency Flashers Control
Turn Signal Lever
Figure 2-3. Controls
Hi-Low Switch
Location (optional)
Accessory Switch
Location (optional)
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2007 Eagle Electric Golf Car Service Manual © December 20072-5
Section 2 - General Information
Service Item Service Method/Check Reference
Vehicle Body Visually, check for damaged or loose hardware. See section 8.
Steering and Linkages Test drive, check for free movement
and proper operation.
Refer to Owner’s Manual index for
specifications.
Warning Labels Visually inspect all labels for readability or missing. Verify labels are in place and readable.
Visually check for wear or damage. Refer to Owner’s Manual index for
Verify proper tire inflation. specifications.
Reverse Warning Buzzer or
In- Motion Beeper
Refer to Owner’s Manual index for
Head, Tail or Flasher, Lights Check for proper operation Verify lights and flashers work.
Check Battery Discharge Indicator indicator (BDI) Refer to Owner’s Manual index for
for battery condition. specifications.
Horn Check for proper operation. See section 8.
PRE-OPERATION INSPECTIONS
Each vehicle has been inspected and adjusted to factory speci-
fications before delivery. Upon receipt of vehicle, perform a pre-
delivery inspection of the vehicle. Also, before using the vehicle,
there are checks that must be performed to ensure that it is in safe
working order.
WARNING
Only trained maintenance professionals should service or
repair this vehicle. Persons doing even simple repairs or
service should have a working knowledge and experience in
general electrical and mechanical repair. Follow all proce-
dures and observe all warnings stated in this manual. Use
caution and common sense.
PRE-OPERATION CHECK LIST
Accelerator/Brake Operation
Tires
Charger Plug and Receptacle
Batteries
Test drive, check free travel and braking action.
Test drive, check for proper operation. Verify an audible sound heard.
See section 6.
Check for damage and snug fit.
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2007 Eagle Electric Golf Car Service Manual © December 20072-6
Section 2 - General Information
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Section 3 –Maintenance
2007 Eagle Electric Golf Car Service Manual
ELECTRIC VEHICLE SERVICE
Always turn power key to off, directional keyswitch 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.
PERIODIC MAINTENANCE
A comprehensive maintenance program is important for the
safe, reliable operation of all Columbia ParCar vehicles. The
recommended procedures described in this service manual
are effective methods for performing periodic maintenance
and repair. The maintenance procedures outlined in this
manual are recommended when servicing the vehicle. Refer
to maintenance check-list for frequency of service. Perform
only those maintenance instructions described in this manual.
If major repairs are needed, contact the local Columbia dealer
for assistance. Columbia dealers have the technical
experience, training and original Columbia vehicle parts for
the vehicle. Always use original Columbia vehicle parts when
servicing the vehicle.
NOTICE: Some procedures require the use of special
tools. These special tools must be used when and
where recommended.
NOTICE: When performing Monthly, Quarterly, Semi-
Annual or Annual maintenance, ensure that Daily and
Weekly inspections are included.
NOTICE: The environment that the vehicle operates in
can vary widely. Severe service operations will require
the periodic maintenance recommendations to be
adjusted to shorter time intervals. The following
calendar is one example of how scheduling routine
maintenance can be managed.
NOTICE: Daily maintenance is performed daily before
operation of vehicle by owner or operator. Weekly
maintenance is performed on a weekly basis to
include all daily maintenances and is performed by
the owner, operator or trained maintenance personnel.
3-1
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Section 3 –Maintenance
2007 Eagle Electric Golf Car Service Manual
3-2
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Section 3 –Maintenance
2007 Eagle Electric Golf Car Service Manual
MAINTENANCE SCHEDULE CHECKLIST - ELECTRICAL
Component
Procedure
Daily*
Weekly
Monthly†
Quarterly†
Semi-
Annual†
Annual†
(25 hours)
(50 hours)
(100 hours)
Batteries
Check charge (fill
cells prior to
charging)
x
Check electrolyte
level
x
Apply equalization
charge to battery
pack
x
Clean terminals and
wash battery case
x
Test batteries
x
Electrical wires
Check for tightness
or damage
x
Reverse warning
buzzer
Check for operation
(use keyswitch)
x
* Service done by Owner † Service done by trained maintenance personnel
MAINTENANCE SCHEDULE CHECKLIST - TIRES & WHEELS
Component
Procedure
Daily*
Weekly
Monthly
†
Quarterly†
(25 hours)
Semi-Annual†
(50 hours)
Annual†
(100 hours)
Tires
Check for wear and
damage
x
Pressure –per tire side
wall
x
Damaged rims
x
Front wheel
alignment
Check & adjust as
needed.
x
Wheels
Check lug nuts
x
Wheel bearing, repack,
replace as needed.
x
Check axle nuts for
tightness & torque
x
Steering
linkage
Check for excessive
movement & that
hardware is secure
x
* Service performed by Owner † Service performed by trained maintenance personnel
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Section 3 –Maintenance
2007 Eagle Electric Golf Car Service Manual
BATTERIES
Batteries may be recharged if vehicle has been driven 15
minutes or more since the previous charge. Before charging,
be sure master power key switch is Off and key is removed
from the switch.
Refer to Chapter 9 for all procedures relating to the batteries.
LUBRICATION
Brake Pedal
The brake pedal assembly has one fitting located under the
vehicle. Apply one pump of grease annually. See Section 5 –
Accelerator and Brake System.
Annually inspect wheel bearings and repack as needed
REAR AXLE
Check the rear axle oil only if signs of leakage are detected.
Change oil at 24 months or 1250 mile (2000 km) intervals,
whichever occurs first. Refer to Section 7.
Capacity - 12 ounces (360 ml). Light weight gear lubricant
SAE #30 oil.
CHASSIS CLEANING
Proper cleaning materials and techniques are vital to the care
of the vehicle. Wash underside of vehicle to remove all dirt
and debris. Wash chassis and body with a mild detergent
only. Do not use abrasives on the paint.
Do not direct high pressure water at the controller,
speed switch, or top of batteries. Dry the controller and
top surfaces of the batteries immediately after
washing.
SEAT CLEANING
Proper cleaning will extend the life of the vehicle seat. Use
mild soap or detergent and a soft sponge to clean whenever
necessary. For stubborn or imbedded dirt, a soft bristle brush
may be used.
NOTICE: Do not use harsh chemicals or abrasives to
clean seat material. Cracking, splitting, or “melting” of
seat materials may occur. If seat material becomes
torn or split, it should be replaced
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Section 3 –Maintenance
2007 Eagle Electric Golf Car Service Manual
LIFTING INSTRUCTIONS
Use extreme caution lifting or working around lifted
vehicle. Vehicle should be lifted only when parked on
a flat, hard and level surface. Do not work under the
vehicle unless it is firmly supported on jack stands.
When lifting the vehicle for service, use a sturdy lifting
device such as a floor jack or hydraulic lift. Always,
wedge wheels and set parking brake of the vehicle to
keep it from rolling. When using a lifting device, lift
only on sturdy parts under the vehicle, an example
being the frame. When using a floor jack, lift only on
sturdy parts under the vehicle, an example being the
frame or axle housing. Place jack stands or sup-port
blocks under vehicle frame to support vehicle weight
for added safety. Watch for cables, linkages or wire
harness.
If any vehicle is raised while loaded, check that the
load is secured before lifting vehicle. Failure to do so
could cause damage to load, vehicle, or personal
injury. Before lifting, always chock tires. Use care to
prevent tipping or rolling over. Be careful not to
damage the brake cables during lifting operation.
Tools Required
- hydraulic trolley jack
- chocks or wooden blocks
- jack stands or support blocks
Hoist Lifts
If a hoist is used to lift the vehicle, check that the hoist is rated
at a capacity greater than the vehicle weight. Lift the vehicle
sufficiently from the floor, 10° to 25° angle, to allow the
placement of jack stands to support the weight of the vehicle
during service. See figure 3-1.
HOISTING THE REAR OF VEHICLE
1. To lift the rear, connect the lifting eyes/hooks to rear
frame tubes at right and left sides. Do not use the bumper
for lifting. Hoist vehicle sufficiently to place jack stands
underneath frame.
2. Place jack stands under frame at right and left sides to
allow access under the vehicle.
3. When work is completed, lift the vehicle and remove the
jack stands, then lower vehicle to the floor.
HOISTING THE FRONT OF VEHICLE
1. To lift the front, connect the lifting eye/hooks to front
frame tubes at right and left sides. Do not use the bumper
for lifting.
2. Place jack stands under frame at right and left sides to
allow access under vehicle.
3. When work is completed, lift the vehicle and remove the
jack stands, then lower vehicle to the floor.
Floor Jack Procedure
If a floor jack is used to lift the vehicle, check that the floor
jack is rated at a capacity greater than the vehicle weight. Lift
the vehicle sufficiently from the floor to allow the placement of
jack stands or wooden blocks and hold the weight of the
vehicle during service.
LIFTING THE REAR OF VEHICLE
1 To lift the rear, place floor jack under the rear axle
housing. Do not use the bumper for lifting. Raise vehicle
sufficiently to place jack stands underneath frame.
2. Place jack stands under frame at right and left sides to
allow access under the vehicle.
3. When work is completed, place floor jack under rear axle
housing, lift the vehicle and remove the jack stands, then
lower vehicle to the floor.
LIFTING THE FRONT OF VEHICLE
1. To lift the front, place floor jack under the heavy leaf
spring retainer plate. Do not use the bumper for lifting.
Raise vehicle sufficiently to place jack stands underneath
frame.
2. Place jack stands under frame at right and left sides to
allow access under the vehicle.
3. When work is completed, place floor jack under leaf
spring retainer plate, lift the vehicle and remove the jack
stands, then lower vehicle to the floor.
Jack Stands
Jack stands need to be of sufficient rated load capacity to hold
the vehicle safely. See Section 2 - Vehicle Specification Chart
for empty vehicle weight.
Figure 3-1
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