© December 2007
5-2
Section 5 - Accelerator & Brake System
2007 Eagle Electric Golf Car Service Manual
ELECTRIC VEHICLE SERVICE
When servicing the electric vehicle always observe the following:
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
ACCELERATOR PEDAL
Accelerator pedal maintenance consists of periodic inspection. No
lubrication or adjustment is necessary.
The accelerator pedal is connected to the brake pedal with a
ratchet and pawl. When the accelerator pedal is depressed, the
brake is released and the system is energized.
The accelerator pedal works in conjunction with the linear accel-
erator and the Sevcon controller to adjust and control vehicle di-
rection and speed.
All adjustments are made using the PCPak or handheld Calibra-
tor.
See Section 4-Troubleshooting
.
MECHANICAL BRAKE SYSTEM
General
The mechanical braking system consists of two rear wheel drum
brakes, the brake pedal, springs and brake cables to operate the
brakes.
A brake equalizer pulls evenly on both brake cables. The brake
equalizer
fl
oats to create equal tension to each brake cable lead-
ing to the rear brake assemblies.
These brakes are self-adjusting and should not require adjustment
if shoe-to-drum clearance is within normal limits. When brakes are
applied, shoes expand outward to drum. If brake shoe travel is
excessive, brake adjuster will advance to compensate for wear.
When brakes are released, adjuster returns to normal position.
To check brake operation, operate the vehicle with no load, in a
large, clear area. Release the accelerator and apply the brake
pedal completely. The vehicle should stop abruptly. If it doesn’t,
see
Mechanical Brake Adjustments
in this section.
The parking brake is applied by depressing the parking brake
pad at the top of the brake pedal which locks the brakes in place.
Brakes are released when the accelerator or brake pedal is de-
pressed. If brakes fail to hold the car in position when parking
brake is applied, see
Mechanical Brake Adjustments
.
Periodic Brake Inspection
Intervals between brake 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 or injury and vehicle damage.
Periodic inspection should always include the following:
1. With vehicle stationary, depress the brake pedal and check
for 1/4” pedal free travel before resistance is felt. Maximum
pedal free travel should not exceed 2” measured from
fl
oor
board to top of pedal. If pedal free travel is excessive, see
Mechanical
Brake Adjustments
.
2. Inspect brake parts under vehicle for physical damage, cor-
rosion, or cable fraying. Inspect dust boot at brake actuating
lever located behind each rear wheel. If cracked or split, re-
place dust boot.
3. Operate 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 indicate malfunctioning brake linkage or
excessive wear to brake shoes.
Annual Brake Inspection
WARNING
To perform this service, raise vehicle using
fl
oor jack and
safely support it with jack stands positioned under main
frame tubes. See
Section 3 - Lifting Instructions
.
1. Perform steps 1 & 2 under
Mechanical Rear Drum Brake Dis-
assembly
.
2. Inspect drum for excessive or uneven wear. Look for cracks
radiating from stud holes.
Maximum drum inside diameter is 6.635” (168.4 mm). If drum
is worn beyond service limit, or uneven wear is shown, drum
must be replaced. See
Brake Drum Service
.
3. Inspect brake shoes for thickness, uneven wear or physical
damage. If brake shoe lining at any point is measured to be
less than 1/16” (1.6 mm), brake shoes must be replaced. See
Mechanical Rear Drum Brake Disassembly.
4. Inspect for oil or grease contamination. Replace brake shoes
that are contaminated. See
Mechanical Rear Drum Brake
Disassembly
.
5. Inspect dust boot at brake actuating lever. If cracked or split,
replace dust boot.
6. Wash mud, brake shoe debris, and dirt from brake assem-
blies and drum. Apply white lithium grease to contact points
between brake shoe and brake back plate. Remove excess
grease to prevent brake shoe contamination.
CAUTION
Do not use compressed air to blow dust from brake assem-
bly. Brake dust contains potentially harmful contaminants.
7. Perform steps 5-8 under
Mechanical Rear Drum Brake Reas-
sembly
.
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