Columbia ParCar P4E-LE-48A Service Manual Download Page 1

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SERVICE MANUAL

Models

Eagle Electric Golf Cars

Models

P4E-LE-48A & P4E-LE-48S

P4E-SE-48A & P4E-SE-48S

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Summary of Contents for P4E-LE-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: ...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 w...

Page 3: ...cing 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 Ca...

Page 4: ...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...

Page 5: ...2007 Eagle Electric Golf Car Service Manual December 2007 iv THIS PAGE INTENTIONALLY LEFT BLANK Find replacement parts for your cart faster at CartPros com...

Page 6: ...ic Golf Car Service Manual December 2007 1 1 Section 1 Safety OVERVIEW 1 2 SAFETY INFORMATION 1 2 SAFETY PREPARATIONS 1 3 ICONS IN PROCEDURES 1 4 DECALS 1 4 Find replacement parts for your cart faster...

Page 7: ...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 batt...

Page 8: ...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 runni...

Page 9: ...mational 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 l...

Page 10: ...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 OPER...

Page 11: ...ting 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 u...

Page 12: ...verse 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 mic...

Page 13: ...se 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 des...

Page 14: ...ery 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 receip...

Page 15: ...2007 Eagle Electric Golf Car Service Manual December 2007 2 6 Section 2 General Information This page intentionally left blank Find replacement parts for your cart faster at CartPros com...

Page 16: ...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 servici...

Page 17: ...Section 3 Maintenance 2007 Eagle Electric Golf Car Service Manual 3 2 Find replacement parts for your cart faster at CartPros com...

Page 18: ...tion 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 An...

Page 19: ...pacity 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 di...

Page 20: ...me 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 HOISTI...

Page 21: ...mage to battery See step 1 SPECIFIC GRAVITY FREEZE POINTS Specific Gravity 1 250 1 225 1 200 1 117 1 110 Electrolyte Freeze Point F C 65 54 F C 39 39 F C 18 28 F C 2 19 F C 17 8 RETURNING VEHICLE TO S...

Page 22: ...listed where the maintenance is to be performed throughout this manual When a specific fastener torque is not specified use the following Torque Table as a general guide in determining proper torque...

Page 23: ...wton meter in lb 0 7376 Length Measurements inch mm 25 4 millimeter in 0 0394 foot m 0 3048 meter ft 3 281 miles kilometers 1 6 kilometers miles 0 621 Liquid Volume Measurements fluid ounces millilite...

Page 24: ...BLESHOOTING 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...

Page 25: ...al number Visually inspect for any obvious signs of hazards such as sharp edges in the body or other parts open wire insulation or wire connections or discolored parts of the vehicle indicating heat o...

Page 26: ...ity when tested at 55 amp draw after a complete recharge cycle The batteries can be cleaned by hose washing with a standard garden hose or with a soft bristle brush ensure battery caps are present and...

Page 27: ...o the main battery pack positive terminal then check the table below Fault Code Condition Correctiive Action Vehicle will not move forward or reverse Vehicle operates slowly Vehicle drives in forward...

Page 28: ...res Fault Code Condition Correctiive Action Vehicle Will Not Move Forward or Reverse continued TROUBLESHOOTING WITH PCPAK With the vehicle power system off connect the PCPak computer diagnostic utilit...

Page 29: ...If the switch fails to close in either direction check the switch with a VOM and the wiring back to the controller Pin 2 for Forward and Pin 3 for Reverse 5 Check the Seat Switch item and value Figure...

Page 30: ...f the switch fails to close check the wiring from the B post of the controller to the seat switch test the seat switch with a VOM and check the wiring back to the controller pin 5 For vehicles without...

Page 31: ...back ON Observe green LED on controller for flashing pattern If flashing count number of flashes and refer to the LED Diagnostic Table on next page No power to controller Full battery voltage Good Con...

Page 32: ...4 No power to contactor coil connections No power from main contactor to controller B Controller connector wiring open circuit Controller connector pin not in place Dielectric break down at connector...

Page 33: ...h left on Check for BDI scan sweep Battery voltage has fallen or risen 24 Volt system 15 V Low 36 5 V High 36 Volt system 22 5 Low 50 V High 48 Volt system 30 V Low 65 V High Defective controller repl...

Page 34: ...i a F r o t c a t n o C h s a l F 4 Replace Solenoid If good Controller replacement required contact Tech Support Contactor Failed or contactor wiring fault Bench test contactor and test contactor wir...

Page 35: ...tate of charge and or replace batter ies If contactor does not close check fuse and wiring to coil Replacement of a defective controller should always be confirmed by verification that other faults ha...

Page 36: ...ccelerator switch pedal needs to be recycled after a direction change Wiring fault two directions selected Pedal depressed when key turned on External strobe flasher light caused fault Wiring polarity...

Page 37: ...place bulb 4 Failed power key switch Test and replace contactor as necessary 5 Inoperable rocker switch Replace rocker switch Speed Switch Pot Box Testing Test Passed Failed Disconnect white and black...

Page 38: ...rings Damaged or contaminated replace Grabbing or pulling replace 4 Air in hydraulic lines hydraulic brakes Bleed hydraulic lines Severe reaction to pedal pressure and uneven stopping 1 Shoes and lini...

Page 39: ...2007 Eagle Electric Golf Car Service Manual December 2007 4 16 Section 4 Troubleshooting This page intentionally left blank Find replacement parts for your cart faster at CartPros com...

Page 40: ...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 Insp...

Page 41: ...ke service and inspection may vary depend ing driving habits type of driving road and climate conditions and vehicle load CAUTION Periodic brake inspection is required to prevent potential ac cident o...

Page 42: ...turn and remove fastener and spring Repeat for other 1 4 turn fastener 5 Grasp two brake shoes at centers Pull them outward and fold away from backing plate Lift one shoe at a time from brake anchor...

Page 43: ...te lithium grease to the threads of automatic adjuster screw and to contact points where brake shoes rest against back plate 2 Install automatic adjuster screw and nut into automatic adjust er assembl...

Page 44: ...ate vehicle on level ground applying brakes to ensure that both rear brakes apply equally Check that excessive force is not required to apply brakes Excessive force required to apply brakes could indi...

Page 45: ...brake handle in up position Make sure release button on handle frees the parking brake lever and that lever returns to full down released position 4 Operate vehicle on level ground applying brakes to...

Page 46: ...or lubricants on hy draulic brake parts as they will contaminate the brake fluid NOTICE Do not mix parts from left and right brake assemblies as they may differ 1 Engage the brake Remove four Tinnerm...

Page 47: ...red To remove see Section 7 Rear Axle and Rear Wheel Assemblies Rebuild or replace wheel cylinder torque spider whenever brake shoes are replaced or more often when required to correct a leak ing cyli...

Page 48: ...luid 4 Handling and storing brake fluid Keep brake fluid clean Do not allow any foreign material in the fluid Prevent any petroleum product gasoline kerosene oil grease etc from contaiminating the bra...

Page 49: ...to en gage the brakes Loosen wheel assembly mounting nuts 2 Raise and secure vehicle as described in Section 3 Lifting Instructions 3 Remove four nuts and front wheel tire assembly 4 Disengage the bra...

Page 50: ...n seals are not harm ful and need not be removed 12 After honing take care in cleaning the caliper parts Flush them with alcohol wipe dry with a clean lint free cloth then flush and dry them again Cle...

Page 51: ...ct free movement MECHANICAL PARKING BRAKE PEDAL ADJUSTMENT NOTE Correct parking brake operation should be confirmed be fore adjustments are made to cables and mechanical linkage Check that corrosion h...

Page 52: ...nstalling 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 Steerin...

Page 53: ...t disc brakes remove caliper top mounting bolt and rotate caliper off of rotor Remove ro tor 5 Remove cotter pin axle nut and flat washer Discard axle nut and cotter pin 6 Carefully pull hub 9 off the...

Page 54: ...hen turning wheel hub then back off until cotter pin can be inserted Grease cap Grease cap Axle nut 5 8 18 Torque to 45 ft lbs then tighten until cotter p in can be inserted Washer 9 16 Front hub Disc...

Page 55: ...to wheel from valve stem side IMPORTANT Cleaning tire and wheel is very important as tubeless tires require a perfect seat to seal 1 Clean tire beads to remove dirt and foreign matter Use a wire brus...

Page 56: ...22 25 ft lbs 3 3 5 Kgm 4 Connect collar to steering wheel with two Phillips head screws RACK AND PINION STEERING ASSEMBLY Removing Rack and Pinion Steering Assembly 1 Remove front body as described i...

Page 57: ...stall tie rod ends to steering arm assemblies Figure 6 8 Install nuts and torque to 25 28 ft lbs 3 5 3 9 Kgm FRONT SUSPENSION Replacing Shock Absorbers Replace shock absorber if dampening affect is no...

Page 58: ...justments as described in Steering and Suspen sion Adjustments STEERING AND SUSPENSION ADJUSTMENTS To perform adjustments place vehicle on flat level surface Posi tion front wheels pointed directly fo...

Page 59: ...e 6 12 Kingpin A arm and Steering Arm Assembly Figure 6 13 Camber Adjusters Camber adjuster dimple tance between front edge of both tires Then check the dis tance between back edge of both tires 3 The...

Page 60: ...ling 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 Disasse...

Page 61: ...1 Place wheel assembly on the hub studs 7 Tighten four lug nuts Figure 7 1 by hand and wrench until snug using a criss cross pattern Figure 7 2 8 Lower the vehicle to the ground and torque the lug nut...

Page 62: ...Removing Rear Axle 1 Before raising vehicle with wheels on the ground break loose the lug nuts Figure 7 1 2 Raise the vehicle and engage the brake 3a Mechanical Drum Brake Remove lug nuts and remove...

Page 63: ...fore cleaning Parts should be cleaned with emulsion cleaners or petro leum based cleaners DANGER Do not use gasoline as a cleaner NOTICE Bearings should not be dried by spinning with compressed air Th...

Page 64: ...2 Bearing ball 9 1 Intermediate Shaft Gear 10 2 O ring Item Qty Description 11 2 Bearing ball 12 1 Input shaft 13 1 Bearing ball 14 3 O ring 15 1 Bearing ball 16 3 Snap ring 17 2 Plug cup 18 1 Cover...

Page 65: ...t damage bear ing surfaces See Figure 7 9 5 Remove the bearing 26 from the axle shaft by supporting the inner race of the bearing in an arbor press Apply pressure to the threaded end of the axle shaft...

Page 66: ...Removing Differential Bearings 10 Using a bearing puller remove differential bearings 8 from each side of the differential case See Figure 7 14 11 Remove four bolts 6 and nuts 7 from the final drive...

Page 67: ...tom of housing for removal 14 Using a brass drift pin drive the intermediate shaft 9 from the flange side of housing Shaft should travel far enough to allow engagement of I D bearing puller 15 Using a...

Page 68: ...gs 13 15 and shaft should slide easily into housing If resistance is encountered use a plastic or leather mallet to tap shaft into position See Figure 7 20 5 Install outer snap ring 16 at input shaft...

Page 69: ...ce a small bead of RTV non acidic silicone sealant to flange of cover plate 18 Sealant should be applied to inside of cover plate mounting holes Figure 7 26 14 Install cover plate 18 with ten bolts 20...

Page 70: ...Figure 7 5 Connect brake ca bles to brake assemblies using new cotter pins clevis pins and e rings 3b Hydraulic Drum Brake Connect hydraulic brake lines to brake assemblies on the rear axle NOTE Afte...

Page 71: ...support it with jack stands positioned under main frame tubes See Section 3 Lifting Instructions Have an oil drain pan handy 1 Remove ten cover plate bolts Figure 7 32 2 Remove cover and drain oil in...

Page 72: ...SHION 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 Directiona...

Page 73: ...e headlight wiring in order to unplug the connector 6 Remove the turn signal lamps by twisting and pulling them free of the front body 7 Remove front body from vehicle Installing Front Body 1 Position...

Page 74: ...wo screws 3 Reinstall front body if removed previously See Installing Front Body BACK RESTS AND FRAME Removing the Back Rests and Frame NOTE Only remove back rest frame if it is bent and requires re p...

Page 75: ...body 1 Raise the center body and rear body to the full upright posi tion 3 Disconnect the power cord at the battery charger If plug is taped remove the electrical tape 4 Cut all cable ties securing th...

Page 76: ...the bag rack out towards the rear and remove it from the rear body TAIL LIGHTS AND REAR TURN SIGNALS Removing Tail Light or Rear Turn Signal 1 Raise rear body to the full upright position 2 Unplug wir...

Page 77: ...refully raise rear body to full upright position Install re straint cable to bag rack mounting stud and secure with nut Figure 8 10 5 Install wiring connectors to the respective tail lights and turn s...

Page 78: ...tch and remove switch from con sole 3 Connect wires to new switch place switch into console and secure with plastic nut Replacing Battery Discharge Indicator BDI 1 Remove two nuts securing wires to BD...

Page 79: ...d screws securing top cover to con trol assembly NOTE The turn signal lever has a spring washer located un derneath and is held in place by the cover Turn signal lever can come off when cover is remov...

Page 80: ...2007 8 9 Section 8 Body and Chassis Figure 8 19 Turn Signal Control Bulb Light bulb retaining brackets Figure 8 20 Turn Signal Control Wiring Retaining screw Spring washer located under lever Find re...

Page 81: ...2007 Eagle Electric Golf Car Service Manual December 2007 8 10 Section 8 Body and Chassis This page intentionally left blank Find replacement parts for your cart faster at CartPros com...

Page 82: ...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 DISCHARGE...

Page 83: ...and discharging 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 Re...

Page 84: ...h clean low pressure water to keep them free of acid spillage dirt and other de bris If vented batteries are used make sure vent caps are secure before washing Do not hose wash electronic control lers...

Page 85: ...er cell of the bat tery 2 Move these tabs in the directions shown in Figure 8 1 NOTICE Do not use SpeedCaps as handles to lift or move battery 3 Check the electrolyte level on brand new batteries befo...

Page 86: ...ttery condition of battery state of discharge temperature of electrolyte Figure 9 3 Special Order Single Point Watering System AC line voltage level and other variables Charging time usually takes 12...

Page 87: ...rain dust solvents thinners or other flammables Install surge arrestors on incoming AC power lines This protects from all but direct or close proximity lightening strikes Do not cover charger cabinet...

Page 88: ...December 2007 9 7 Section 9 Batteries and Battery Charger 2007 Eagle Electric Golf Car Service Manual Figure 9 5 Algorithm Table Find replacement parts for your cart faster at CartPros com...

Page 89: ...Also review the Battery Mainte nance Procedures 6 When the yellow 80 LED is lit the Charger has completed the bulk stage and the batteries are at approximately 80 state of charge The 80 LED remains o...

Page 90: ...dicates a thermostatic control has limited the charger output due to ambient temperature conditions It is still charging but at a reduced rate CHARGING PROCEDURE 1 Check electrolyte level in all cells...

Page 91: ...wer first when moving the posi tive negative alligator clips to prevent a spark from igniting the gas emitted from the batteries Be sure to charge all of the batteries in the set Each battery may requ...

Page 92: ...st not be used even for short runs prior to Dis charge Load Test Electrolyte level must be correct in all cells DISCHARGE LOAD TEST PROCEDURE WARNING Discharge Load Test must be performed in well vent...

Page 93: ...ively insoluble as long as the specific gravity of electrolyte is kept above 1 125 specific gravity but if allowed to drop below this value the lead sulfate becomes increasingly soluble and may migrat...

Page 94: ...ss See Figure 9 12 Plug in cord from power inlet to charger pigtail Tape the two plugs togeth er so they cannot accidentally separate 4 Bundle up the excess charger output cable and secure it neatly w...

Page 95: ...December 2007 9 14 Section 9 Batteries and Battery Charger 2007 Eagle Electric Golf Car Service Manual This page intentionally left blank Find replacement parts for your cart faster at CartPros com...

Page 96: ...0 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...

Page 97: ...nal drive axle must be periodically lubricated with a thin layer of quality anti seize compound 3 Check for any signs of oil leaks from final drive axle which might cause oil to enter traction motor I...

Page 98: ...ve 4 brush plate screws Figure 10 7 Push brush ter minal studs through into the center of the head as the brush box brushes and terminal assemblies are removed See ex ploded view Figure 10 9 8 Remove...

Page 99: ...of movement in the holder New brush length 1 20 30 5 mm Minimum brush length 0 60 15 2 mm Replacement brush length less than 0 60 15 2 mm If any brushes are worn to the point that replacement is nece...

Page 100: ...ar Service Manual Figure 10 9 Traction Motor 1 Cap 2 Head 3 Bearing 4 Snap Ring 5 Brush Assembly 6 Brush Box Assembly 7 Motor Frame 8 Pole Shoe 9 Shunt Coil field coil 10 Armature Figure 10 10 Undercu...

Page 101: ...y Columbia Inspection Motors that have been disassembled for servicing should also in clude a complete inspection of the frame and field assembly It is not uncommon for the frame and field assembly of...

Page 102: ...ion 1 Coat open end of the armature and rear axle input shaft with Anti Seize compound Insert a new rubber bumper into open end of armature Place motor into vehicle and onto input shaft 2 Rotate motor...

Page 103: ...tely excited DC motor the system provides optimized power efficiency through pedal proportional speed control and regenera tive braking This control system is ideal for hilly terrain or areas with mul...

Page 104: ...heck of the vehicle s driving abili ties CONTACTOR SOLENOID This solenoid is an electro magnetic switch that energizes when current is applied to the small control circuit terminals When en ergized th...

Page 105: ...December 2007 10 10 2007 Eagle Electric Golf Car Service Manual Section 10 Traction Drive System This page intentionally left blank Find replacement parts for your cart faster at CartPros com...

Page 106: ...A member of the Nordic Group of Companies 1115 Commercial Avenue Reedsburg WI 53959 Phone 608 524 8888 Fax 608 524 8380 www parcar com Find replacement parts for your cart faster at CartPros com...

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