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Columbia ParCar P4E-SE-48A User Manual

Columbia ParCar P4E-SE-48A
106 pages
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SERVICE MANUAL
Models
Eagle Electric Golf Cars
Models
P4E-LE-48A & P4E-LE-48S
P4E-SE-48A & P4E-SE-48S
© December 2007
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Table of Contents

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Columbia ParCar P4E-SE-48A Specifications

General IconGeneral
BrandColumbia ParCar
ModelP4E-SE-48A
CategoryOffroad Vehicle
LanguageEnglish

Summary

Section 1 - Safety

Overview

General introduction to safety statements in the manual.

Safety Information

Key safety recommendations to be observed at all times for safe operation.

Safety Preparations

Procedures to follow before servicing to prevent accidental startup and injury.

Icons in Procedures

Explanation of icons used in procedures to indicate hazards.

Decals

Information on ordering and replacing safety, warning, and informational decals.

Section 2 - General Information

Model Information

Details about different golf car models and their specifications.

Vehicle Model Information

Table detailing models, VIN digits, name, use type, and power system.

Vehicle Identification Number (VIN) Charts

Explanation of VIN structure and how to identify vehicle details.

Safety Committee

Recommendations for forming a safety committee for vehicle operation.

Vehicle Specifications

Technical specifications for P4E-LE and P4E-SE models.

Controls and Operation

Description of vehicle controls and basic operation.

Location of Controls

Diagram showing the location of various vehicle controls.

Operation

Step-by-step guide for operating the vehicle.

Pre-operation Inspections

Checks to ensure the vehicle is in safe working order before use.

Pre-operation Check List

List of items to check before operating the vehicle.

Section 3 – Maintenance

Electric Vehicle Service

General safety precautions for servicing electric vehicles.

Periodic Maintenance

Importance of a comprehensive maintenance program for safe and reliable operation.

Maintenance Schedule Checklist - Body/Frame/Chassis

Scheduled maintenance tasks for body, frame, and chassis components.

Maintenance Schedule Checklist - Operating Controls

Scheduled maintenance tasks for steering, brakes, and controls.

Maintenance Schedule Checklist - Electrical

Scheduled maintenance tasks for batteries and electrical systems.

Maintenance Schedule Checklist - Tires & Wheels

Scheduled maintenance tasks for tires and wheels.

Maintenance Schedule Checklist - Electric Motor

Scheduled maintenance tasks for the electric motor.

Maintenance Schedule Checklist - Fluids

Scheduled maintenance tasks related to vehicle fluids.

Batteries

Procedures and checks related to vehicle batteries.

Lubrication

Lubrication points and schedule for vehicle components.

Lifting Instructions

Safety precautions and procedures for lifting the vehicle.

Vehicle Storage

Guidelines for storing electric vehicles to maintain battery life.

Returning Vehicle to Service

Steps to follow when taking a stored vehicle back into service.

Transporting a Vehicle

Safety recommendations for trailering or transporting the vehicle.

Torques and Metric Conversion Factors

Table of torque specifications and conversion factors.

Section 4 - Troubleshooting

Pre-Troubleshooting Steps

Essential steps to follow before diagnosing any vehicle problem.

Battery Testing

Procedures for testing the vehicle's batteries to ensure proper function.

Troubleshooting Specific Complaints

Common issues and systematic approaches to diagnose them.

Vehicle Will Not Move; Forward or Reverse

Diagnostic steps for when the vehicle fails to move.

Troubleshooting with PCPAK

Using the PCPak diagnostic utility for troubleshooting.

Troubleshooting with the Handheld Calibrator

Using the handheld calibrator for diagnosing issues.

Vehicle Will Not Move; Forward or Reverse - LED Diagnostic Guide

Interpreting LED flash codes for troubleshooting movement issues.

ACEplus Sevcon Controller Power System - 6 Post

Troubleshooting specific to the ACEplus controller power system.

Smartdrive Sevcon Controller Power System - 5 Post

Troubleshooting specific to the Smartdrive controller power system.

LED Fault Code Diagnostic Guide

Interpreting controller LED flash codes for fault diagnosis.

Speed Switch (Pot Box) Testing

Procedure for testing the speed switch (pot box).

Component Troubleshooting

Troubleshooting individual components causing vehicle problems.

Power Outlet

Troubleshooting steps for issues with the vehicle's power outlet.

Brakes

Troubleshooting steps for slow or incomplete brake release.

Section 5 - Accelerator & Brake System

Accelerator Pedal

Information and maintenance for the accelerator pedal.

Mechanical Brake System

Details on the rear drum brake system, adjustments, and maintenance.

General

Overview of the mechanical braking system components.

Periodic Brake Inspection

Routine checks for the mechanical brake system.

Annual Brake Inspection

Annual inspection procedures for the mechanical brake system.

Mechanical Rear Drum Brake

Disassembly and reassembly of the rear drum brake.

Brake Cable Replacement

Procedure for replacing brake cables.

Mechanical Brake Adjustments

Adjustments for mechanical brake linkage and parking brake.

Hydraulic Brake System

Details on the hydraulic brake system, including inspection and maintenance.

General

Overview of the hydraulic braking system components.

Periodic Brake Inspection

Routine checks for the hydraulic brake system.

Annual Brake Inspection

Annual inspection procedures for the hydraulic brake system.

Hydraulic Rear Drum Brake

Disassembly and reassembly of the hydraulic rear drum brake.

Hydraulic Master Cylinder

Maintenance and bleeding procedures for the hydraulic master cylinder.

Hydraulic Front Disc Brake

Information on front disc brake systems and replacing pads.

Hydraulic Brake Adjustments

Adjustments for hydraulic brake linkage and parking brake.

Section 6 - Front Wheels, Steering & Front Suspension

General

Basic description of steering and front suspension systems.

Specifications

Technical specifications for steering gear, camber, and toe-in adjustments.

Front Wheels and Hubs

Procedures for removing, inspecting, and installing front wheels and hubs.

Removing Front Wheels and Hubs

Steps to remove front wheels and hubs from the vehicle.

Inspecting/Replacing Wheel Hub Bearings

Procedures for inspecting and replacing wheel hub bearings.

Installing Front Wheel Hubs and Wheels

Steps to install front wheel hubs and wheels.

Tires

Information on tire removal, installation, and inflation.

General

Overview of tire maintenance and handling.

Removing Tire

Procedure for removing a tire from the wheel rim.

Installing Tire

Procedure for installing a tire onto the wheel rim.

Steering Wheel

Procedures for removing and installing the steering wheel.

Removing Steering Wheel

Steps to remove the steering wheel from the steering shaft.

Installing Steering Wheel

Steps to install the steering wheel onto the steering shaft.

Rack and Pinion Steering Assembly

Procedures for servicing the rack and pinion steering assembly.

Removing Rack and Pinion Steering Assembly

Steps to remove the steering assembly from the vehicle frame.

Disassembling Rack and Pinion Steering Assembly

Procedure for taking apart the rack and pinion steering assembly.

Assembling Rack and Pinion Steering Assembly

Procedure for reassembling the rack and pinion steering assembly.

Installing Rack and Pinion Steering Assembly

Steps to install the steering assembly back into the frame.

Front Suspension System

Procedures for replacing suspension components.

Replacing Shock Absorbers

Steps to replace front shock absorbers.

Replacing Front Leaf Spring

Steps to replace the front leaf spring.

Disassembling Kingpin, Steering Arm and A-Arm

Procedure for disassembling steering and suspension components.

Steering and Front Suspension Adjustments

Procedures for adjusting steering and suspension alignment.

Camber Adjustment

Procedure for adjusting the camber angle of the front wheels.

Toe In Adjustment

Procedure for adjusting the toe-in alignment of the front wheels.

Section 7 - Rear Wheels, Rear Suspension and Axle Assembly

Rear Wheels

Procedures for removing, inspecting, and installing rear wheels.

Removing Rear Wheels

Steps to remove rear wheels from the vehicle.

Rear Axle Wheel Bearings

Information on rear axle wheel bearings and replacement.

Installing Rear Wheels

Steps to install rear wheels onto the vehicle.

Tires

Reference to tire procedures in Section 6.

Rear Suspension

Procedures for replacing rear suspension components.

Replacing Rear Shock Absorbers

Steps to replace rear shock absorbers.

Replacing Rear Springs

Steps to replace the rear leaf springs.

Replacing Rear Frame Bushings

Procedure for replacing rear frame bushings.

Rear Axle Assembly

Procedures for removing, disassembling, assembling, and installing the rear axle.

Removing Rear Axle

Steps to remove the rear axle assembly from the vehicle.

Disassembling Rear Axle

Procedure for taking apart the rear axle assembly.

Assembling Rear Axle

Procedure for reassembling the rear axle assembly.

Installing Rear Axle

Steps to install the rear axle assembly into the vehicle.

Rear Axle Differential Oil

Procedure for changing the differential oil.

Changing Differential Oil

Steps for draining and refilling the differential oil.

Section 8 - Body and Chassis

Front Body

Procedures for removing and installing the front body section.

Removing Front Body

Steps to remove the front body from the vehicle.

Installing Front Body

Steps to install the front body onto the vehicle.

Replacing Front Headlight Bulb

Procedure for replacing the front headlight bulb.

Replacing Front Turn Signal Bulb

Procedure for replacing the front turn signal bulb.

Front Bumper

Procedures for removing and installing the front bumper.

Removing the Front Bumper

Steps to remove the front bumper from the vehicle.

Installing the Front Bumper

Steps to install the front bumper onto the vehicle.

Back Rests and Frame

Procedures for removing and installing back rests and frame.

Removing the Back Rests and Frame

Steps to remove back rests and frame components.

Installing the Back Rests

Steps to install back rests and frame components.

Seat Cushion and Handrails

Procedures for removing and installing seat cushions and handrails.

Center Body

Procedures for removing and installing the center body section.

Removing Center Body

Steps to remove the center body from the vehicle.

Installing Center Body

Steps to install the center body onto the vehicle.

Bag Rack

Procedure for removing the bag rack.

Removing Bag Rack

Steps to remove the bag rack from the rear body.

Tail Lights and Rear Turn Signals

Procedures for removing and installing tail lights and turn signals.

Removing Tail Light or Rear Turn Signal

Steps to remove tail lights or turn signals.

Installing Tail Light or Rear Turn Signal

Steps to install tail lights or turn signals.

Rear Body

Procedures for removing and installing the rear body section.

Removing Rear Body

Steps to remove the rear body from the vehicle.

Installing Rear Body

Steps to install the rear body onto the vehicle.

Rear Bumper

Procedure for installing the rear bumper.

Console Controls

Procedures for replacing various console control switches.

Replacing Power On Off Key Switch

Steps to replace the power on/off key switch.

Replacing Directional Key Switch

Steps to replace the directional key switch.

Replacing Headlight Switch

Steps to replace the headlight switch.

Replacing Battery Discharge Indicator (BDI)

Steps to replace the Battery Discharge Indicator (BDI).

Steering Wheel

Procedures for removing and installing the steering wheel.

Horn

Procedures for replacing the horn button and horn assembly.

Turn Signal / Emergency Flasher Control

Procedures for disassembling and assembling the turn signal control.

Section 9 - Batteries and Battery Charger

Safety

Essential safety precautions when working with batteries and chargers.

General Information

Overview of battery types and their functions.

Battery Types

Information on deep cycle lead-acid batteries used in electric vehicles.

Electric Vehicle Battery

Description of how electric vehicle batteries function.

Battery Inspection

Recommended frequency and procedure for inspecting batteries.

Battery Cleaning

Procedures for cleaning battery terminals and battery tops.

Battery Service (Water)

Guidelines for adding distilled water to batteries.

General

Factors affecting battery maintenance recommendations.

Adding Water To Battery

Step-by-step instructions for adding water to battery cells.

Battery Charging

Information and procedures for charging vehicle batteries.

General

Overview of battery charging principles and safety.

Charger Safety Information

Safety warnings related to using the battery charger.

Delta-Q Charger Operation

Detailed operation guide for the Delta-Q charger.

Red Light Charger Error Codes

Explanation of error codes indicated by the charger's red light.

Charging Procedure

Step-by-step guide for charging the vehicle batteries.

Special Charging Procedure For Excessively Discharged Batteries

Procedure for charging severely discharged batteries.

Testing Batteries

Methods for testing battery condition and performance.

Testing with a Charger

Using the charger to test the overall battery bank condition.

Specific Gravity Test

Using a hydrometer to measure specific gravity for battery testing.

Hydrometer Test

Detailed steps for performing a hydrometer test on battery cells.

Discharge (Load) Test

Procedure for performing a load test to determine battery condition.

Storing Batteries

Guidelines for properly storing batteries.

Replacing Batteries

Procedures for removing and installing vehicle batteries.

Battery Charger

Procedures for removing and installing the battery charger.

Removal

Steps to remove the battery charger from the vehicle.

Installation

Steps to install the battery charger onto the vehicle.

Section 10 - Traction Drive System

Traction Motor

Maintenance, inspection, and servicing procedures for the traction motor.

Maintenance

Recommended maintenance schedule for the traction motor.

External Motor Inspection

Checks for external motor components and connections.

Internal Motor Inspection

Inspection of internal motor parts like brushes and commutator.

Traction Motor Removal

Steps to remove the traction motor from the vehicle.

Traction Motor Disassembly

Procedure for taking apart the traction motor.

Armature Inspection

Inspection of the motor armature for wear and damage.

Armature Testing

Tests to perform on the armature for electrical faults.

Brushes

Inspection and replacement procedures for motor brushes.

Brush Springs

Procedure for checking brush spring tension and alignment.

Bearing

Recommendation for replacing motor bearings.

Frame and Field Coils

Inspection and maintenance of the motor frame and field coils.

Traction Motor Reassembly

Procedure for reassembling the traction motor.

Traction Motor Installation

Steps to install the traction motor back into the vehicle.

Controller

Information on the vehicle's controller system and troubleshooting.

Smartdrive Traction Motor System

Description of the Smartdrive controller system.

ACEplus Traction Motor System

Description of the ACEplus controller system.

Controller Testing

Procedure for testing the controller while installed in the vehicle.

Removing the Controller

Steps to remove the vehicle controller.

Installing the Controller

Steps to install the vehicle controller.

Contactor/Solenoid

Procedures for removing and installing the contactor/solenoid.

Removing the Contactor

Steps to remove the contactor from the vehicle.

Installing the Contactor

Steps to install the contactor onto the vehicle.