© December 2007
5-9
Section 5 - Accelerator & Brake System
2007 Eagle Electric Golf Car Service Manual
Figure 5-9. Hydraulic Brake Caliper Bleeder Valve
Front hydraulic wheel
cylinder bleeder valve
right side.
4. Check that brake shoes are correctly positioned into the slots
provided in each master cylinder piston.
5. 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. Push the drum
fully onto the assembly.
6. Apply pressure to the brake pedal, pumping 2-3 times and re-
leasing, then check to see if additional adjustment is required
to create drag on the drum. Adjust as necessary to achieve
slight drag on the drum.
7. When adequate drag is achieved (very slight drag), install
drum fully onto brake assembly and install four new Tinner-
man nuts.
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 5-8). Repeat for
other rear wheel. Recheck lug nut torque with vehicle on the
ground.
Hydraulic Master Cylinder
BRAKE FLUID MAINTENANCE
1. Maintain
fl
uid level within 1/4” of master cylinder
fi
ller opening
(Figure 5-6).
2. Changing
brake
fl
uid:
As a result of use, brake
fl
uid loses some of its original quali-
ties and may become contaminated. When performing major
brake work to the hydraulic system, remove old
fl
uid and re-
place it with clean brake
fl
uid.
Brake
fl
uid must be changed following extended usage or
contamination. Anytime
fl
uid looks milky or dark, there are
contaminants in the
fl
uid.
If any of the hydraulic system parts are corroded, or the
fl
uid
is discolored,
fl
ush the hydraulic system to remove old
fl
uid,
then
fi
ll with clean brake
fl
uid.
3. Soft or swollen rubber parts, or milky or discolored
fl
uid indi-
cate the brake
fl
uid is contaminated.
Drain
old
fl
uid from the system.
Replace cups and seals.
Flush hydraulic system with clean brake
fl
uid.
Re
fi
ll system with clean brake
fl
uid.
4. Handling and storing brake
fl
uid:
Keep
brake
fl
uid clean. Do not allow any foreign material in
the
fl
uid.
Prevent any petroleum product (gasoline, kerosene, oil,
grease, etc.) from contaiminating the brake
fl
uid.
Use only clean containers for dispensing brake
fl
uid.; Do not
use containers contaminated with dirt, grease, etc.
Always cover or cap brake
fl
uid containers when not actually
dispensing the
fl
uid. If containers are left open or uncovered,
the
fl
uid absorbs moisture from the air.
Never reuse old brake
fl
uid drained from the system. Used
brake
fl
uid is contaminated to some extent.
Store
brake
fl
uid containers in a clean, dry place.
BLEEDING THE HYDRAULIC SYSTEM
WARNING
Brake
fl
uid can cause irritation of eyes and skin, and may be
harmful if swallowed. If
fl
uid is swallowed, induce vomiting
by administering two tablespoons of salt in a glass of warm
water. Call a doctor. In case of contact with skin or eyes,
fl
ush
with plenty of water. Get medical attention for eyes. KEEP
BRAKE FLUID OUT OF THE REACH OF CHILDREN!
If any line or cylinder has been opened when servicing the brake
system, or when satisfactory brake adjustment is unobtainable, or
pedal is spongy, bleed air from the hydraulic system as follows:
1. Install a length of appropriate size plastic tubing over the
wheel cylinder bleeder valve (Figure 5-9).
NOTE: On vehicles equipped with only rear hydraulic brakes,
bleed the right side wheel
fi
rst. On vehicles equipped with both
front and rear hydaulic brakes, bleed both right side wheels
fi
rst,
then both left side wheels.
2. Place the other end of tubing in any clear glass jar containing
about 1/2” of brake
fl
uid.
3. Open bleeder valve by rotating it counterclockwise about 1/2
turn. With master cylinder full of
fl
uid at all times, slowly de-
press the brake pedal repeatedly until
fl
uid
fl
ows from bleeder
valve free of air bubbles.
4. Add
fl
uid to master cylinder to bring 1/4” from cover. Close
bleeder valve. Repeat procedure on left wheel.
5. Do not reuse
fl
uid unless it is clear and free of sediment. If it
is impossible to bleed all air from system, master cylinder is
faulty and a master cylinder repair kit should be installed.
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