© December 2007
5-5
Section 5 - Accelerator & Brake System
2007 Eagle Electric Golf Car Service Manual
6. Apply pressure to the brake pedal and release, then check to
see if additional adjustment is required to create drag on the
drums.
7. When adequate drag is achieved (very slight drag), install-
wheel hub and drum fully onto brake assembly and install
spacer. Engage brake and install a new axle nut. Tighten axle
nut to a minimum 65 ft. lbs. (23 Nm) Install new cotter pin.
8. Reinstall rear wheel/tire assembly and four lug nuts. En-
gage brake and tighten lug nuts in a criss-cross pattern to a
maximum 65-70 ft. lbs. (23-25 Nm) (Figure 5-3). Repeat for
other rear wheel. Recheck lug nut torque with vehicle on the
ground.
Brake Cable Replacement
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. At rear brake assembly (Figure 5-4), remove cotter pin, clevis
pin and e-ring (23) from brake cable clevis. Discard cotter pin
and e-ring.
2. Remove cable clevis from rear wheel brake actuator arm. Cut
cable tie securing brake cables to frame.
3. Remove brake cable from equalizer (Figure 5-5).
4. Repeat for other cable.
5. In order to install new cables, it may be necessary to loosen
equalizer on brake rod (Figure 5-5). Note position of jamnut
on equalizer and mark with tape. Loosen jamnut on rod end
to provide slack to brake cable.
6. Install brake cable ends at brake equalizer.
7. Route brake cables to rear axle brake actuator arms (Figure
5-4). Secure cable clevis end to each arm with clevis pin and
new cotter pin. Secure cable sheath with new e-ring.
8. Secure brake cables to frame with new cable tie.
9. Tighten nut on brake rod (Figure 5-5) to position marked in
step 5. With vehicle stationary, depress the brake pedal and
check for 1/4” pedal free travel before resistance is felt. Maxi-
mum pedal free travel should not exceed 2” measured from
fl
oor board to top of pedal. If adjustment is required, see
Me-
chanical Brake Linkage Adjustment
below.
10. 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.
Mechanical Brake Adjustments
MECHANICAL BRAKE LINKAGE ADJUSTMENT
NOTE: Correct brake operation should be con
fi
rmed before ad-
justments are made to cables and mechanical linkage. Check that
corrosion has not caused excessive resistance in the operation
of the brake cables. If corrosion is present, replace cables before
performing adjustments.
1. Loosen jamnuts on brake rod connecting brake pedal to
equalizer.
2. Rotate brake rod to shorten or lengthen it. Adjust length of
brake rod until free brake pedal movement is less than 1/4”.
3. Tighten
jamnuts.
MECHANICAL PARKING BRAKE PEDAL ADJUSTMENT
After rear brake operation is tested, and brake linkage and cables
are properly adjusted, check and adjust the parking brake as fol-
lows:
1. Look through the
fl
oor opening while gently pressing on the
brake pedal. The gap between the brake ratchet end and the
brake ratchet pawl should be no greater than 1/16”-1/8” (Fig-
ure 5-5).
2. If adjustment is required, remove the clevis pin securing the
brake rod to the brake pedal. If the gap between the parking
brake ratchet and the brake pawl is less than 1/16”, shorten
the rod slightly to adjust. If the gap is greater than 1/8”, length-
en the rod to adjust.
3. Reconnect the brake rod to the parking brake pedal. Recheck
the space to verify correct gap.
4. Depress the parking brake pedal until the
fi
rst click is heard.
At this setting the vehicle should not roll when on a slight in-
cline. Depress the pedal to the second click, or notch. With
the parking brake set, the vehicle should not roll on a steep
incline or hill.
5. With the gap properly set, if the vehicle does move on when
performing steps 4 & 5, perform the
Mechanical Brake Link-
age Adjustment
above.
M
ECHANICAL DRUM BRAKE SHOE ADJUSTMENT
These brakes are self-adjusting and require no manual adjust-
ment. If brakes do not adjust automatically, check brake cable
adjustment or inspect brake assembly for internal damage or fric-
tion.
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