No, the motor cannot be removed from the Columbia ParCar P4E-SE-48A without disassembling other parts. It requires loosening and removing bolts, washers, and pulling the motor away from the rear axle housing. Assistance is recommended due to the motor's weight.

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Summary of Contents for Columbia ParCar P4E-SE-48A

Page 1 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...
Page 2: Model Identification
In addition to the information given in this manual, Service Bul- vehicle. See Section 2-General Information for VIN location and letins are issued to Columbia ParCar dealers, which cover interim additional information. engineering changes and supplementary information. Service Bul-...
Page 3: Table Of Contents
Table of Contents SECTION 1 - SAFETY SECTION 5 - ACCELERATOR AND BRAKES Overview................. 1-2 Accelerator Pedal ..............5-2 Safety Information ..............1-2 Mechanical Brake System ............5-2 Safety Preparations ..............1-3 General................5-2 Icons in Procedures ..............1-4 Periodic Brake Inspection............ 5-2 Decals..................
Page 4 Table of Contents Toe In Adjustment ..............6-7 Battery Service (Water) ............9-4 SECTION 7 - REAR WHEELS, REAR SUSPENSION Battery Charging..............9-5 & AXLE ASSEMBLY Delta-Q Charger Operation ............ 9-8 Rear Wheels ................7-2 REd Light Charger Error Codes ..........9-8 Removing Rear Wheels ............
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Page 6 Section 1 - Safety OVERVIEW ................... 1-2 SAFETY INFORMATION ..............1-2 SAFETY PREPARATIONS ..............1-3 ICONS IN PROCEDURES ..............1-4 DECALS ....................1-4 2007 Eagle Electric Golf Car Service Manual © December 2007 Find replacement parts for your cart faster at CartPros.com...
Page 7: Section 1 - Safety
Accordingly, anyone who uses a service procedure or tool which Batteries contain acid which can is not recommended by Columbia ParCar must ﬁ rst thoroughly cause severe burns. Causes severe satisfy him/herself that neither their nor the operator’s safety will burns.
Page 8: Safety Preparations
Cautions appear throughout this manual indicating possible hazards or unsafe practices that may result in minor personal Working on Columbia ParCar vehicles without following injury, damage to vehicles or property. proper procedures and using proper lifting equipment may result in vehicle damage or personal injury.
Page 9: Icons In Procedures
Section 1 - Safety ICONS IN PROCEDURES Refer to Figures 1-1 for location of the decal. Watch out for icons and symbols in procedures. They are there to Use a heat gun or hair dryer to soften up and remove any help you avoid situations that might expose you to an unneces- damaged sticker.
Page 10: Section 2 - General Information
Section 2 - General Information MODEL INFORMATION ............... 2-2 Vehicle Model Information ..................Vehicle Identiﬁ cation Number (VIN) Charts ............SAFETY COMMITTEE• ................. 2-2 VEHICLE SPECIFICATIONS ..............2-3 CONTROLS AND OPERATION ............2-4 Location of Controls ....................Operation ......................... PRE-OPERATION INSPECTIONS ............2-5 PRE-OPERATION CHECK LIST ............
Page 11: Safety Committee
Section 2 - General Information MODEL INFORMATION Vehicle Model Information Model Group Name Power Identiﬁ ers Type System VIN Digits P4E-LE Eagle Golf Car Battery 48 Volt P4E-SE Eagle Golf Car Battery VIN Label 48 Volt Vehicle Identiﬁ cation Number (VIN) Charts Digit 1 - 3 Figure 2-1.
Page 12: Vehicle Speciﬁ Cations
VEHICLE SPECIFICATIONS • Deﬁ ne who should and who should not drive the vehicles. Columbia ParCar Corporation reserves the right to change spec- • Decide what to do should an unsafe condition or operating iﬁ cations, equipment or designs at any time without notice and problem be discovered.
Page 13: Controls And Operation
Section 2 - General Information CONTROLS AND OPERATION Depress accelerator with the right foot. Location of Controls To stop the vehicle, release the accelerator pedal and apply the brake pedal slowly and completely. Figure 2-3 shows the location of the vehicle’s controls. Operation WARNING NOTICE...
Page 14: Pre-Operation Inspections
Section 2 - General Information PRE-OPERATION INSPECTIONS WARNING Each vehicle has been inspected and adjusted to factory speci- Only trained maintenance professionals should service or ﬁ cations before delivery. Upon receipt of vehicle, perform a pre- repair this vehicle. Persons doing even simple repairs or delivery inspection of the vehicle.
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Page 16: Section 3 - Maintenance
PERIODIC MAINTENANCE maintenance can be managed. 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.
Page 17 Section 3 – Maintenance 2007 Eagle Electric Golf Car Service Manual Find replacement parts for your cart faster at CartPros.com...
Page 18 Section 3 – Maintenance MAINTENANCE SCHEDULE CHECKLIST - ELECTRICAL Semi- Component Procedure Daily* Weekly Monthly Quarterly Annual † † † Annual † (25 hours) (100 hours) (50 hours) Check charge (fill cells prior to charging) Check electrolyte level Apply equalization Batteries charge to battery pack...
Page 19: Batteries
Section 3 – Maintenance BATTERIES CHASSIS CLEANING Batteries may be recharged if vehicle has been driven 15 Proper cleaning materials and techniques are vital to the care minutes or more since the previous charge. Before charging, of the vehicle. Wash underside of vehicle to remove all dirt be sure master power key switch is Off and key is removed and debris.
Page 20: Lifting Instructions
Section 3 – Maintenance 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.
Page 21: Vehicle Storage
Section 3 – Maintenance VEHICLE STORAGE RETURNING VEHICLE TO SERVICE: Reconnect battery negative terminal. Turn Power keyswitch OFF. Remove Power key during Fully recharge batteries. storage to prevent unintentional starting of vehicle. Check tire pressure and readjust if necessary. Perform initial maintenance per periodic maintenance in Do not attempt to charge a battery that is frozen or if the beginning of this section.
Page 22: Torques And Metric Conversion Factors
Section 3 – Maintenance TORQUES AND METRIC CONVERSION FACTORS use the following Torque Table as a general guide in determining proper torque. When a metric equivalent is not Individual component torques and metric equivalents are listed, use the Conversion Factors Chart to convert to metric listed where the maintenance is to be performed throughout values.
Page 23 Section 3 – Maintenance Conversion Factors Chart Into Metric Out of Metric to convert from Multiply by to convert from Multiply by Work force measurements inch-pound N. m. 0.1130 Newton-meter in. lb. 8.8496 foot-pound N. m. 0.3558 Newton-meter in. lb. 0.7376 Length Measurements inch...
Page 24: Section 4 - Troubleshooting
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 2007 Eagle Electric Golf Car Service Manual ©...
Page 25: Pre-Troubleshooting Steps
Section 4 - Troubleshooting ELECTRIC VEHICLE SERVICE When servicing your electric vehicle always observe the follow- ing: SAFETY FIRST Always turn Power key to OFF, Directional 16-Pin key switch to Neutral, remove Power key, Connector Controller block tires and disconnect the battery Status Light negative (-) cable before performing any vehicle service to avoid accidental startup...
Page 26: Battery Testing
Section 4 - Troubleshooting BATTERY TESTING The ﬁ rst step in sevicing any electric vehicle that is not operating properly is to completely test the batteries. The batteries are the source of power for the vehicle drive and auxiliary systems, therefore are the most integral part of the electric vehicle troubleshooting. Battery testing should be done as follows and in the order as follows Inspect/TestCondition Corrective Action...
Page 27: Troubleshooting Speciﬁ C Complaints
Section 4 - Troubleshooting ● Vehicle will not move; forward or reverse TROUBLESHOOTING SPECIFIC COMPLAINTS ● Vehicle operates slowly The ﬁ rst step in sevicing any electric vehicle that is not operating Troubleshooting is a matter of investigation and deduction based ●...
Page 28 Section 4 - Troubleshooting Vehicle Will Not Move; Forward or Reverse (continued) Fault Code Condition Correctiive Action Fault code light steady ON Indicates the controller is powered 1. Check to make sure the parking brake is releasing and the vehicle will not roll when pushed on a level surface. up and ready to perform.
Page 29 Section 4 - Troubleshooting TROUBLESHOOTING WITH PCPAK (continued) Check the FS1 Switch input on the same screen. With the accelerator at rest, the value for the FS1 Switch should read “open”. When the accelerator pedal is pressed, the value should change to “closed” (Figure 4-4). If the value fails to close, check the FS1 wiring circuit and test the switch with a VOM.
Page 30 Section 4 - Troubleshooting check the FS1 wiring circuit and test the switch with a VOM. TROUBLESHOOTING WITH THE HANDHELD CALIBRATOR Check the wiring back to the controller (Pin 4). Connect the handheld calibrator to the vehicle and enter the “Read-Only”...
Page 31: Aceplus Sevcon Controller Power System
Section 4 - Troubleshooting Vehicle Drives Slowly Good brushes are square • Check for all physical/visual signs of damage, low tire pres- cut and not worn sure or jammed linkages. • Check for brake drag by turning vehicle power off, releasing parking brake, and attempting to roll vehicle a short dis- tance.
Page 32 Section 4 - Troubleshooting LED Fault Code Diagnostic Guide The Sevcon Controller Flash Code Diagnostic Guide can be used to get an initial indication of a problem. In some cases, there are multiple possible causes for a fault in that category. The causes and veriﬁ cation steps for some fault codes related to system input or circuitry for the drive system are listed.
Page 33 Section 4 - Troubleshooting Sevcon Newer (Beta) 633T45303 6 Post Controller - 6 Post (continued) Green LED Possible Fault Condition Handset Cause/Test/Failure Flashes 7 Flash Low or high battery voltage 13/16 End of charge cycle with Power switch left on. Check for BDI scan sweep.
Page 34 Section 4 - Troubleshooting 2007 Eagle Electric Golf Car Service Manual 4-11 © December 2007 Find replacement parts for your cart faster at CartPros.com...
Page 35: Smartdrive Sevcon Controller Power System
Section 4 - Troubleshooting Smartdrive SEVCON CONTROLLER POWER SYSTEM - 5 POST IMPORTANT: Always follow troubleshooting guide in exact sequence as listed. Performing tests out of sequence will cause inaccurate results and lost time in diagnosing electrical system problems. Troubleshooting Guide Test Passed Failed...
Page 36 Section 4 - Troubleshooting LED Fault Code Diagnostic Guide The Sevcon Controller Flash Code Diagnostic Guide can be used to get an initial indication of a problem. In some cases, there are multiple possible causes for a fault in that category. The causes and veriﬁ cation steps for some fault codes related to system input or circuitry for the drive system are listed.
Page 37: Speed Switch (Pot Box) Testing
Section 4 - Troubleshooting SPEED SWITCH (POT BOX) TESTING - ALL MODELS Speed Switch (Pot Box) Testing Test Passed Failed Disconnect white and black lead wires 0-50 ohms resistance = Good Greater than 50 ohms, refer to Pot Switch adjustment. If from wire harness to speed switch un- adjustment does not correct, replace pot switch or speed der front body.
Page 38 Section 4 - Troubleshooting Wheel bearings. Power Outlet Damaged or contaminated-replace. Fuse failed. Grabbing or pulling-replace. Check fuse and replace if failed. Air in hydraulic lines (hydraulic brakes). Open wiring or failed connection. Bleed hydraulic lines. Check wiring and connections Severe reaction to pedal pressure and uneven stopping.
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Page 40 Section 5 - Accelerator & Brake System ACCELERATOR PEDAL ..............5-2 MECHANICAL BRAKE SYSTEM ............5-2 ....................5-2 General ..............5-2 Periodic Brake Inspection ..............5-2 Annual Brake Inspection ..............5-3 Mechanical Rear Drum Brake ..............5-5 Brake Cable Replacement .............5-5 Mechanical Brake Adjustments HYDRAULIC BRAKE SYSTEM ............5-6 ....................5-6 General ..............5-6...
Page 41: Accelerator Pedal
Section 5 - Accelerator & Brake System ELECTRIC VEHICLE SERVICE CAUTION Periodic brake inspection is required to prevent potential ac- When servicing the electric vehicle always observe the following: cident or injury and vehicle damage. SAFETY FIRST Periodic inspection should always include the following: With vehicle stationary, depress the brake pedal and check for 1/4”...
Page 42: Mechanical Rear Drum Brake
Section 5 - Accelerator & Brake System Mechanical Rear Drum Brake Wheel hub MECHANICAL REAR DRUM BRAKE DISASSEMBLY Brake drum ● Before removal of existing parts, note location of colored springs and other parts for correct reassembly. Spacer Axle nut and ●...
Page 43 Section 5 - Accelerator & Brake System if surface variance exceeds .005” on the side. if hard spots cause noticeable effects such as pedal pulsa- tions or brake roughness. If spots are severe, replace drum. if heat checking is plainly visible or can be felt with a ﬁ nger- nail.
Page 44: Brake Cable Replacement
Section 5 - Accelerator & Brake System Mechanical Brake Adjustments Apply pressure to the brake pedal and release, then check to see if additional adjustment is required to create drag on the MECHANICAL BRAKE LINKAGE ADJUSTMENT drums. NOTE: Correct brake operation should be conﬁ rmed before ad- When adequate drag is achieved (very slight drag), install- justments are made to cables and mechanical linkage.
Page 45: Hydraulic Brake System
Section 5 - Accelerator & Brake System HYDRAULIC BRAKE SYSTEM Master cylinder General The hydraulic brake system utilizes a combination of mechani- cal and hydraulic components and are equipped with rear drum brakes. In addition, vehicles can also be equipped with additional front disc brakes.
Page 46 Section 5 - Accelerator & Brake System ● Always lay out brake shoes and other parts in order re- brake shoe and set it aside. moved. Reinstall in same order. Remove the blue spring holding the top of each brake shoe ●...
Page 47 Section 5 - Accelerator & Brake System and wheel cylinder is recommended only when replacement is CAUTION required. To remove, see Section 7 - Rear Axle and Rear Wheel Do not depress brake pedal while shoes and drum are re- Assemblies.
Page 48: Hydraulic Master Cylinder
Section 5 - Accelerator & Brake System right side. Check that brake shoes are correctly positioned into the slots provided in each master cylinder piston. Install the brake drum 3/4 over the brake assembly and using a brake spoon or brake adjusting tool, rotate the brake ad- juster until drag is felt against the brake drum.
Page 49: Hydraulic Front Disc Brake
Section 5 - Accelerator & Brake System Hydraulic Front Disc Brake Caliper mounting bolts Disc brakes are not adjustable and rarely cause problems. If prob- lems are encountered, refer to the following service and inspec- tions procedures for possible causes and solutions. REPLACING BRAKE PADS CAUTION Do not depress brake pedal while brake pads are removed...
Page 50 Section 5 - Accelerator & Brake System Remove brake pad mounting bolts (Figure 5-10). 12. After honing, take care in cleaning the caliper parts. Flush them with alcohol, wipe dry with a clean lint-free cloth, then Remove old pads and replace with new pads. ﬂ...
Page 51: Hydraulic Brake Adjustments
Section 5 - Accelerator & Brake System Hydraulic Brake Adjustments HYDRAULIC BRAKE LINKAGE ADJUSTMENT Gently depress brake pedal and check for free movement before master cylinder piston is depressed. If there is no free travel in the pedal before the master cylinder plunger begins to move, or if the free travel of the pedal exceeds 3/8”, adjustment of the brake rod will be required.
Page 52: Section 6 - Front Wheels, Steering & Front Suspension
Section 6 - Front Wheels, Steering & Front Suspension GENERAL .....................6-2 SPECIFICATIONS .................6-2 FRONT WHEELS AND HUBS ..............6-2 ............6-2 Removing Front Wheels and Hubs ..........6-2 Inspecting/Replacing Wheel Hub Bearings ..........6-2 Installing Front Wheel Hubs and Wheels TIRES ....................6-4 ....................6-4 General ..................6-4 Removing Tire ..................6-4...
Page 53: General
Section 6 - Front Wheels, Steering & Front Suspension ELECTRIC VEHICLE SERVICE On vehicles equipped with front disc brakes, remove caliper top mounting bolt and rotate caliper off of rotor. Remove ro- When servicing the electric vehicle always observe the following: tor.
Page 54 Section 6 - Front Wheels, Steering & Front Suspension Spindle Cotter pin 1/8 x 1 Front hub Non-Disc brake model Roller bearing Lug nut, 1/2-20 Tighten to 45 ft. lbs. Axle nut, 5/8-18 Tighten until resistance is felt when turning wheel hub, then back off until Roller bearing cotter pin can be inserted...
Page 55: Tires
Section 6 - Front Wheels, Steering & Front Suspension TIRES General In the event of a ﬂ at tire, remove wheel assembly from vehicle. In- ﬂ ate tire to 20 psi (1.33 Atm). Immerse wheel assembly in water to determine point of leak. Mark leak location. If tire can be repaired, use the following procedure to remove and install tire.
Page 56: Steering Wheel
Section 6 - Front Wheels, Steering & Front Suspension Inﬂ ate tire to correct tire pressure (listed on tire sidewall) and immerse wheel/tire assembly in water to check for leaks. 10. Place wheel assembly on the hub studs. 11. Tighten four lug nuts by hand and wrench until snug using a criss-cross pattern (Figure 6-2).
Page 57: Assembling Rack And Pinion Steering Assembly
Section 6 - Front Wheels, Steering & Front Suspension Clean all parts in cleaning solvent. Assembling Rack and Pinion Steering Assembly Steering assembly mounting nuts Refer to Figure 6-11 for the following steps. Using a good quality wheel bearing grease, liberally lubricate all steering parts and inside of steering housing.
Page 58: Assembling Kingpin, Steering Arm And A-Arm
Section 6 - Front Wheels, Steering & Front Suspension Tie rod end Jamnut Oil seal Large Bearing retaining ring Pinion gear Tie Rod Housing Rack gear Bearing Bearing Tie Rod Clamp Lockwasher Boot Retaining washer Figure 6-11. Rack and Pinion Assembly NOTE: Always check that camber is correct before performing Assembling Kingpin, Steering Arm and A-Arm wheel toe adjustment.
Page 59 Section 6 - Front Wheels, Steering & Front Suspension Spacer Washer Camber Adjuster Washer Washer Spacer A-arm Washer Washer A-arm mounting bolt Washer Cotter pin Camber Kingpin nut Washer Adjuster Spacer Bolt Washer Washer A-arm mounting bracket Leaf spring Retainer Bolt bracket Kingpin...
Page 60 Section 7 - Rear Wheels, Rear Suspension and Axle Assembly REAR WHEELS ..................7-2 ...............7-2 Removing Rear Wheels ..............7-2 Rear Axle Wheel Bearings .................7-2 Installing Rear Wheels TIRES ....................7-2 REAR SUSPENSION ................7-2 ............7-2 Replacing Rear Shock Absorbers ...............7-2 Replacing Rear Springs ............7-3 Replacing Rear Frame Bushings REAR AXLE ASSEMBLY ..............7-3...
Page 61: Section 7 - Rear Wheels, Rear Suspension
Section 7 - Rear Wheels, Rear Suspension and Axle Assembly ELECTRIC VEHICLE SERVICE When servicing the electric vehicle always observe the following: SAFETY FIRST 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.
Page 62: Replacing Rear Frame Bushings
Section 7 - Rear Wheels, Rear Suspension and Axle Assembly Bolt Shock Absorber Rear Spring Bolt B Washer Bolt A Bushing Washer Bolt Bolt C Bolt Rear Frame Figure 7-3. Rear Suspension Replacing Rear Frame Bushings Wheel hub Place a hydraulic jack under the rear frame assembly where Brake drum it attaches to the frame.
Page 63: Disassembling Rear Axle
Section 7 - Rear Wheels, Rear Suspension and Axle Assembly 6b. Hydraulic Drum Brake: Disconnect hydraulic brake lines from brake assemblies on the rear axle. Clevis Remove four nuts, bolts and washers securing rear axle to rear frame. E-ring CAUTION Cotter pin Rear axle is heavy and awkward to move.
Page 64 Section 7 - Rear Wheels, Rear Suspension and Axle Assembly Item Qty. Description Item Qty. Description Item Qty. Description Bearing, ball Sealant, anaerobic Carrier Sub-Assy. Input shaft Axle shaft Bearing cap Bearing, ball Nut, brake, 160mm Bolt, bearing cap O-ring Oil seal Diff.
Page 65 Section 7 - Rear Wheels, Rear Suspension and Axle Assembly Figure 7-8. Removing Axle Shaft/Bearing Assembly Figure 7-7. Removing Outer Snap Ring DISASSEMBLING REAR AXLE DANGER Safety glasses should be worn at all times when disassem- bling and assembling the axle. All callout numbers in steps refer to Figure 7-6.
Page 66 Section 7 - Rear Wheels, Rear Suspension and Axle Assembly Figure 7-11. Removing Cover Plate Figure 7-14. Removing Differential Bearings Figure 7-12. Removing Bearing Caps Figure 7-15. Removing Output Gear from Differential Figure 7-13. Removing Differential Assembly Figure 7-16. Removing Cup Plugs 10.
Page 67 Section 7 - Rear Wheels, Rear Suspension and Axle Assembly Figure 7-17. Removing Snap Rings Figure 7-19. Input Shaft Bore Snap Ring Figure 7-18. Removing Intermediate Shaft 12. Punch or drill a 1/8” diameter hole near the center of each intermediate cup plug (17).
Page 68: Assembling Rear Axle
Section 7 - Rear Wheels, Rear Suspension and Axle Assembly Figure 7-23. Installing Bearings on Input Shaft Figure 7-22. Removing O-rings from Intermediate Shaft & Gear 21. Clean the axle housing and carrier cover (18) with lint-free rags. Remove all traces of old silicone sealant from sealing surface of cover and housing.
Page 69 Section 7 - Rear Wheels, Rear Suspension and Axle Assembly Position differential case assembly (4) with ﬂ anged side trun- nion face down on work surface. Align output gear (5) mount- ing holes with differential case. Install four bolts (6) and nuts (7).
Page 70: Installing Rear Axle
Section 7 - Rear Wheels, Rear Suspension and Axle Assembly Figure 7-29. Installing Inner Snap Ring Figure 7-30. Installing Bearings on Axle Shaft 22. Apply Anti-Seize compound to the splines before installing the drum/hub. Installing Rear Axle CAUTION Rear axle is heavy and awkward to move. Get help lifting and installing axle to prevent possible personal injury.
Page 71: Rear Axle Differential Oil
Section 7 - Rear Wheels, Rear Suspension and Axle Assembly REAR AXLE DIFFERENTIAL OIL Changing Differential Oil Differential oil must be changed at least once a year under normal vehicle usage. If vehicle is operated under extreme conditions, or for more than 8 hours a day, oil should be changed twice a year. It is not necessary to remove the axle to change the differential oil.
Page 72: Section 8 - Body And Chassis
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 ........................
Page 73: Front Body
Section 8 - Body and Chassis ELECTRIC VEHICLE SERVICE When servicing the electric vehicle always observe the following: SAFETY FIRST 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 Front body vehicle service to avoid accidental startup...
Page 74: Front Bumper
Section 8 - Body and Chassis Top mounting nuts Mounting screws Figure 8-4. Front Bumper Top Mounting Nuts Figure 8-3. Front Bumper Bottom Mounting Screws FRONT BUMPER Removing the Front Bumper NOTE: It is not necessary to remove the front body to remove the front bumper, but it will make it easier to access the two top mounting bolts.
Page 75: Seat Cushion And Handrails
Section 8 - Body and Chassis SEAT CUSHION AND HANDRAILS Removing Seat Cushion and Handrails Raise center body to full upright position. Remove four nuts, washers and studs securing seat cushion and hand rails to center body (Figure 8-6). Remove seat cushion and two handrails. Seat cushion and handrails mounting Installing Seat Cushion and Handrails...
Page 76: Bag Rack
Section 8 - Body and Chassis Remove nut and cable One additional washer at each mounting hole between rack and body Strap mounting Bag rack locknut and washer mounting hardware Figure 8-10. Bag Rack Mounting Figure 8-9. Middle Body Strap Mounting BAG RACK Tail light Removing Bag Rack...
Page 77: Rear Body
Section 8 - Body and Chassis REAR BODY Removing Rear Body Raise the center body to the full upright position. Raise rear body to the full upright position. Disconnect the wiring connectors from both tail lights and turn signals (Figure 8-11). Rear hinge mounting Remove nut and restraint cable from mounting stud (Figure 8-10).
Page 78: Replacing Directional Key Switch
Section 8 - Body and Chassis Replacing Directional Key Switch Replacing Battery Discharge Indicator (BDI) NOTE: The directional key is non-removeable. If the switch is in- Remove two nuts securing wires to BDI. operable, it is necessary to break the key off the switch to remove Remove two nuts and bracket securing BDI to console.
Page 79: Horn
Section 8 - Body and Chassis HORN Replacing Horn Button Horn button Pull the steering column cover away from the column to ex- mounting pose the wiring and horn mounting hardware (Figure 8-16). hardware Remove the horn button mounting hardware and disconnect the wires from the horn button.
Page 80 Section 8 - Body and Chassis Light bulb retaining brackets Spring washer located under lever Retaining screw Figure 8-19. Turn Signal Control Bulb Figure 8-20. Turn Signal Control Wiring 2007 Eagle Electric Golf Car Service Manual © December 2007 Find replacement parts for your cart faster at CartPros.com...
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Page 82: Section 9 - Batteries And Battery Charger
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 ..............
Page 83: Safety
Section 9 - Batteries and Battery Charger ELECTRIC VEHICLE SERVICE Always wear approved eye protection when working around When servicing the electric vehicle always observe the following: batteries. Do not smoke around batteries. SAFETY FIRST 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...
Page 84: General Information
Section 9 - Batteries and Battery Charger WARNING • Battery must be clean and dry. Dirt and electrolyte on top of battery causes battery to self discharge. Clean battery top The gases produced by a storage battery on charge are high- with baking soda (sodium bicarbonate) and water solution (5 ly explosive.
Page 85: Battery Service (Water)
Section 9 - Batteries and Battery Charger pressure hose does not remove the direct. Rinse with clean water. Take care to ensure that the baking soda mixture does not enter the vent opening in the battery caps. Make sure that the battery tops are clean and dry before put- ting the batteries into storage.
Page 86: Battery Charging
Section 9 - Batteries and Battery Charger Special Order Single Point Watering System AC line voltage level, and other variables. Charging time usually - Factory or Dealer Installed takes 12 hours. New batteries need up to four hours more charg- ing time than “mature”...
Page 87 Section 9 - Batteries and Battery Charger • Charge batteries in well ventilated area. • Install surge arrestors on incoming AC power lines. This protects from all but direct or close proximity lightening • Ventilation fans should be located at the highest point strikes.
Page 88 Section 9 - Batteries and Battery Charger Figure 9-5. Algorithm Table 2007 Eagle Electric Golf Car Service Manual © December 2007 Find replacement parts for your cart faster at CartPros.com...
Page 89: Delta-Q Charger Operation
Section 9 - Batteries and Battery Charger DELTA-Q CHARGER OPERATION Connect power cord at charger receptacle to properly ground- ed wall outlet. NOTICE Connect the charger AC cord to a source capable of supplying 15 amperes minimum per charge (20 amperes recommend- ed).
Page 90: Charging Procedure
Section 9 - Batteries and Battery Charger register less than 5.85 volts, or accumulative total pack voltage has been discharged to less than 20% remaining. Vehicle opera- tion will cease until batteries are recharged. See Special Proce- dure for Excessively Discharged Batteries in this section. 3 Flash Charge Timeout: The charging did not complete in allowed time, 12-14 hours.
Page 91: Special Charging Procedure For Excessively Discharged Batteries
Section 9 - Batteries and Battery Charger Be sure to charge all of the batteries in the set. Each battery Power percentage available from fully charged may require 2-3 hours of charging to bring it back to serviceable batteries at various temperatures condition.
Page 92 Section 9 - Batteries and Battery Charger Hydrometer readings are affected by the temperature of the elec- trolyte being tested. Measure the temperature of the electrolyte, and correct the readings as follows: Above 80ºF: Add .004 to the speciﬁ c gravity readings for each 10º above 80ºF (26ºC).
Page 93: Storing Batteries
Section 9 - Batteries and Battery Charger Interconnecting cables STORING BATTERIES • Batteries can remain in vehicle. • Batteries should be fully charged. • Clean battery tops and connections. Figure 9-9. Battery Cables • Fully charged batteries should be stored in as cold of an en- vironment as possible.
Page 94 Section 9 - Batteries and Battery Charger Nylock nut Flat washer Hold down plate Upper mounting Upper mounting hardware Lower mounting hardware bracket (located behind charger) Figure 9-11. Charger and Bracket Hold down rod Figure 9-10. Battery and Hold Downs Installation Position new charger to mounting bracket.
Page 95 Section 9 - Batteries and Battery Charger This page intentionally left blank. 2007 Eagle Electric Golf Car Service Manual 9-14 © December 2007 Find replacement parts for your cart faster at CartPros.com...
Page 96: Section 10 - Traction Drive System
Section 10 - Traction Drive System TRACTION MOTOR ................10-2 ..................10-2 Maintenance ..............10-2 External Motor Inspection ..............10-2 Internal Motor Inspection ..............10-2 Traction Motor Removal .............. 10-3 Traction Motor Disassembly ................. 10-3 Armature Inspection ................10-4 Armature Testing ..................
Page 97: Traction Motor
Section 10 - Traction Drive System ELECTRIC VEHICLE SERVICE When servicing the electric vehicle always observe the following: SAFETY FIRST 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.
Page 98: Traction Motor Disassembly
Section 10 - Traction Drive System See Figure 10-2. Carefully support motor to prevent it from falling, and loosen and remove three bolts, lock washers and ﬂ at washers securing motor to rear axle/differential housing. Pull motor away from rear axle housing and lift it clear of the Hole plug vehicle.
Page 99: Armature Testing
Section 10 - Traction Drive System Armature Testing Before the armature is reassembled into the motor, the following test should be performed. Check armature for grounded circuits by placing one test lead of a Dielectric Breakdown Tester, also referred to as a “growl- er”, on the commutator and other lead at armature shaft.
Page 100: Bearing
Section 10 - Traction Drive System Head Bearing Snap Ring Brush Assembly Brush Box Assembly Motor Frame Pole Shoe Shunt Coil (ﬁ eld coil) 10. Armature Figure 10-9. Traction Motor Figure 10-10. Undercutting the Armature 2007 Eagle Electric Golf Car Service Manual 10-5 ©...
Page 101: Bearing
Section 10 - Traction Drive System Figure 10-11. Checking Armature for Grounded Circuits Bearing Figure 10-12. Checking Armature for Shorted Windings After the motor has been disassembled, it is recommended that a new bearing be installed. Bearing may appear and feel ok, how- ever, bearing may have been damaged during removal.
Page 102: Traction Motor Installation
Section 10 - Traction Drive System Figure 10-15. Press Bearing and End Cover onto Assembly place, preventing interference and damage to commutator Figure 10-16. Spring Hooks for Brush Springs and brushes during armature installation. Press motor head and bearing onto armature, pressing only against inner race of the bearing.
Page 103: Controller
Section 10 - Traction Drive System F1 and F2 terminals are 1/4-20 UNC while A1 and A2 termi- nals are 5/16-18 UNC. Attach cables with ﬂ at washers, lock washers and hex nuts. Torque A1 & A2 cable attaching nuts to 110 in. lbs. (12.4 N m), while holding the bottom nut, with a thin open-end wrench.
Page 104: Installing The Controller
Section 10 - Traction Drive System ACEplus: Remove six metric bolts, lock washers, ﬂ at washers 16-pin and all the cables and wires connected to the controller. connector Remove 16 pin controller connector at port B in the lower left Mounting bolts hand corner of the controller (Figure 10-23).
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Columbia ParCar P4E-SE-48A Service Manual

Section 1 - Safety

Section 2 - General Information

Section 3 - Maintenance

Section 4 - Troubleshooting

Section 5 - Accelerator and Brakes

Section 6 - Front Wheels, Steering & Front Suspension

& Axle Assembly

Section 7 - Rear Wheels, Rear Suspension

Section 8 - Body and Chassis

Section 9 - Batteries and Battery Charger

Section 10 - Traction Drive System

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