2007 Eagle Electric Golf Car Service Manual
© December 2007
ii
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
Speci
fi
cations ......................................................................... 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 Identi
fi
cation Number (VIN) Charts ......................... 2-2
Safety Committee ................................................................... 2-2
Vehicle Speci
fi
cations ............................................................. 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 Speci
fi
c Complaints ..................................... 4-4
ACE
Plus
Sevcon Controller Power System ........................... 4-8
Smart
drive
Sevcon Controller Power System ...................... 4-12
Speed Switch (Pot Box) Testing ........................................... 4-14
Component Troubleshooting ................................................ 4-14
Find replacement parts for your cart faster at
CartPros.com
