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P4E
Columbia ParCar P4E User Manual
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Service Manual
P
ART
NO. 99496-96
3-00
Gasoline and Electric
Golf and Industrial
Four Wheel V
ehicles
2
Table of Contents
Safety
3
Table of Contents
4
Notes, Cautions, Warnings and Dangers
6
Overview
6
General and Maintenance Information
10
Vehicle and Model Information
12
Vehicle Identification Number (VIN) Matrix
13
General Vehicle Specifications
14
Controls and Operation
17
Location of Controls
17
Notes from General Vehicle Specifications
17
Safety Committee
17
Pre-Operations Inspections
18
Pre-Operations Check List
19
What to Do if You Find a Problem
19
Torque Table
20
Torques and Metric Conversion Factors
20
Conversion Factors
21
Floor Jack
21
Hoist Lifts
21
Lifting Instructions
21
Gasoline Vehicles
22
Hydraulic Floor Lift - Frame Lift
22
Jack Stands
22
Vehicle Storage
22
Electric Vehicles
23
Preparing Vehicle for Extended Storage
23
Returning Vehicle to Service
23
Powermaster Towing Instructions
24
Towing and Transporting Vehicles
24
Maintenance Schedule Checklist
25
Periodic Maintenance
25
Periodic Service Calendar
25
Air Filtration System
27
Chassis Lubrication
27
Engine Cooling
27
Gas Vehicles
27
Air Cleaner Assembly
28
Engine Oil
29
Fuel and Oil Recommendations
29
Sae Viscosity Grades
29
Check Oil Level
30
Cooling System
30
Engine Oil, Lubrication
30
Maintenance
30
Accelerator Micro Switch Adjustment
31
Accelerator/Throttle System Overview
31
Adust Accelerator Micro Switch
31
Differential Oil Fill and Check Hole
31
Adjust Accelerator Cable
32
Adjust Throttle Cable
32
Cable Adjustment - Typical
32
Throttle Cable Connection to Carburetor
32
Governor Arm & Spring
33
Governor Components
33
Governor System
33
Periodic Maintenance and Inspection
33
Battery Charging
34
Electric Vehicle (EV) Charger Operation
34
Electric Vehicle Service
34
Governor Adjustment
34
Prolonging Battery Life
35
Battery Cleaning
36
Battery Watering
36
Electric Vehicle Recommended Maintenance Procedures
36
Bodies, Seats & Components
37
Chassis Lubricaton
37
Front Body Removal
37
Refinishing
37
Bag Rack
38
MID and Rear Bodies
38
MID-Body - Golf/Commercial
38
Seat and Handrail
38
Body Guides
39
Front Hinge Brackets
39
Industrial Rear Bodies
39
Rear Body Hinge
39
Steering, Suspension, & Frame
41
Adjustment and Service Specifications
43
General Information
43
Steering and Suspension
43
Steering System
43
Steering Wheel
43
Disconnect Steering Shaft
44
Disconnect Tie Rod Ends
44
Front Wheels and Hubs
44
Rack and Pinion Steering Assembly
44
Front Hub Removal
45
Front Suspension
45
Front Wheel Hub
45
Bearing Replacement
47
Center Leaf Spring
47
Rack and Pinion Assembly
47
Rack and Pinion Assembly Repair
47
Camber Adjustment
48
Steering and Suspension Adjustment
48
Tire and Wheel Assembly
48
Break Bead of Tire from Wheel
49
Remove Tire
49
Rear Springs
50
Rear Suspension
50
Shock Absorbers
50
Tire Inflation
50
Engine Mount Plate Assembly
51
Rear Fork
51
Rear Fork Bushing and Bolt
51
Frame
52
Servicing
52
Brake Systems
53
Table of Contents
54
Annual Maintenance Inspection
55
Mechanical Braking System
55
Mechanical Drum Brake Assembly
55
System Overview
55
Brake and Park Brake Adjustment
56
Mechanical Brake Linkage
56
Mechanical Park Brake Adjustment
56
Brake Assembly Service
57
Brake Cables
57
Disassembly and Assembly Tips
57
Mechanical Drum Shoe Adjustment
57
Dragging Brakes
58
Severe Reaction to Pedal Pressure and Uneven Stoping
58
Squealing, Clicking or Scraping Noises Upon Application of Brakes
58
Trouble Shooting
58
Hydraulic Braking System
59
Hydraulic Drum Brake Assembly
59
Light Switch Pressure Sensor
59
Hydraulic Brake Linkage
60
Master Cylinder Protective Boot
60
Periodic Maintenance Inspection
60
Brake Shoe Adjustment
61
Hand Operated Parking Brake
61
Mechanical Parking Brake Linkage
61
Parking Brake Handle
61
Brake Shoe Service
62
General
62
Hydraulic Drum Brake Components
62
Brake Drum Service
63
Wheel Cylinder Components
63
Wheel Cylinder Service
63
Bleeding Hydraulic System
64
Brake Fluid Maintenance
64
Hydraulic Master Cylinder
64
Bleeder Fitting
65
Trouble Shooting
65
Disc Brake Components
66
Hydraulic Disc Brake System
66
Periodic Inspection
66
Rear Disc Park Brake Actuating Lever
66
Hydraulic Brake Linkage Adjustment
67
Periodic Maintenance Inspection
67
Brake Caliper Service
68
Brake Disc Service
68
Disc Brake Service
68
Brake Fluid Maintenance
69
Remove Disk Brake Pad
69
Disc Brakes
70
Hydraulic System Master Cylinder
69
Torque Converter/Transmission System
71
Torque Convertor Transmission
72
Drive Belt
72
Drive Clutch
72
Operation of Drive System
72
Primary Drive Assembly
73
Clutch Sheave Wear
73
Secondary Driven Clutch
74
Cam Shoe Inspection
74
Torque Converter/Transmission Alignment
75
Transmission Shift System and Final Drive Axles
76
Transmission Shift System
77
Overview of Operation
77
Console Shift Assembly
77
Starting System Lockout
77
Console Shifter Assembly
78
Console Shifter Adjustment
78
Remove and Install Shift Cable
78
Shift Cable Adjustment
79
Minor Adjustment
79
Route Cable to Passenger Side, Frame Rail
79
Transaxle Shift Bracket and Springs
79
Removal of Transaxle
80
Body Hinge
80
Service Procedure for Transaxle Assembly
80
Gas Vehicle Final Drive Axle Assembly
80
Throttle Cable
81
Transaxle Shift Lever and Springs
81
Remove Drive Belt
81
Jack Stand under Fork Tube
81
Remove Wheel
82
Remove ‘E’ Clips
82
Remove Transaxle Mount Bolts
82
Drain Oil
82
Remove Counter Shaft, Gear and Spacer
83
Case Bolts
83
Governor
83
Protect Shaft
83
Removing Input Shaft
84
Remove Snap Ring from Axle Housing
84
Input Shaft Assembly
84
Remove Axle from Case
84
Differential
85
Differential Components
85
Center Shaft Assembly When Disassembled
85
Assembly of Transaxle
85
Assembly Input Shaft
86
Differential Assembly
86
Spring Pin
86
Center Shaft Assembly
86
Differential Gear
87
Governor Fork Assembly
87
Center Shaft Assembly with Shift Fork
87
Assemble Gear Case
87
Bolt Diagram
88
Installation of Axle Assembly
88
Install Counter Shaft Assembly
88
Position Spacer
88
Gas Vehicle Final Drive Assembly
90
Precautions for Disassembly
90
Bearings and Seals
90
Snap Rings
90
Exploded View
91
Remove Detent Screw
92
Remove Axle and Axle Housing
92
Support with Input Shaft down
92
Remove Housing Bolt
92
Carrier Assembly with Right Case
93
Remove Differential
93
Carrier Half Without Differential
93
Disassemble Intermediate Shaft
93
Remove Input Shaft
94
Reverse Idler Gear and Washer
94
Remove Reverse Idler Gear
94
Remove Snap Ring
94
Remove Governor Shaft
95
Input Shaft and Components
95
Remove Governor Backing Plate
95
Assemble Governor Backing Plate
95
Remove Bearings
96
Remove Differential Gear
96
Install Oil Seals
96
Install Bearings
96
Install Governor Shaft
97
Install Governor Lock Pin
97
Install Shift Actuator Shaft
97
Install Input Shaft
97
Install Snap Ring
98
Install Intermediate Shaft and Fork
98
Install Detent Ball, Spring and Screw
98
Install Intermediate Shaft Components
98
Torque Axle Housing Bolts
99
Install Differential Assembly
99
Torque Carrier Bolts
99
Electric Vehicle Final Drive Axle Assembly
100
General Precautions for Disassembly
100
Cleaning and Inspection
100
Oil Check and Change Intervals
100
Axle Components
102
Outer Snap Ring Removal
102
Spindle Nut Removal
102
Axle Shaft, Bearing, and Oil Seal
102
Axle Bearing Removal
103
Cover Plate Screws Removal
103
Separate Cover Plate from Housing
103
Bearing Caps Removal
103
Differential Bearings Removal
104
Remove Gear from Differential Case
104
Remove Dust Cover
104
Snap Ring Removal
104
‘O’ Rings Removal
105
Intermediate Bearings Removal
105
Input Shaft Removal
105
Intermediate Shaft “O” Ring Removal
105
Input Shaft Bearing Installation
106
Reinstall Input Shaft
106
Install Outer Snap Ring
106
Differential Gear Assembly
106
Install Differential Case
107
Seal and Install Cover Plate
107
Install Dust Cover Plugs
107
Install Shaft Seals
107
Gas & Electric Heavy Duty Axle Shaft & Bearing Service
108
Components of the One-Piece Shaft
108
Brake Drum Removal
108
Remove Brake Assembly Hardware
108
Center Punch Retaining Ring
109
Drill Retaining Ring
109
Remove Axle and Brake Assembly
109
Inner Axle Shaft Seal Removal
109
Components of One-Piece Axle Shaft
110
One-Piece Axle Shaft
110
Axle and Brake Assembly Components
110
Support Bearing Assembly
110
New Grease Seal Assembly
111
Install Axle and Brake Assembly
111
Press Retaining Rings
111
Place Retaining Ring on to Axle
111
Columbia Parcar/Briggs & Stratton Engines
112
Handy Repair Check Chart
120
In the Interest of Safety
122
Theory of Operation
123
Gasoline
123
Oil Viscosity Grades
123
Oil, Lubrication
124
Change Oil (Crankcase)
124
Dipstick and Oil Fill Tube
124
Tune-Up Procedure
125
Overhaul Procedure
126
Check Carburetion
128
Check-Up
128
Check Ignition (Using Engine Starter)
128
Check Compression
128
Carburetor, 9 & 13 H.p. Engines
129
Carburetor, Theory of Operation
129
Float System Operation
129
Idle System Operation
129
Part Throttle Operation
130
High Speed System Operation
130
Choke System Operation
130
Service Briggs & Stratton/ 9 H.p. Carburetor - (Mikuni Carburetor)
131
Removing Fuel Hose and Clamp
131
Removing Bowl
131
Removing Bowl Gasket
131
Removing Pilot Jet
132
Removing Limiter and Idle Mixture Valve
132
Nozzle Removal
132
Removing Main Jet and Nozzle
132
Assemble Carburetor - 9 H.P. Engine
133
Remove Throttle Valve and Shaft
133
Clean Fuel System
133
Install Choke Shaft and Valve
134
Install Pilot Jet
134
Install Idle Mixture Valve
134
Install Float Bowl Gasket
135
Assemble Float Needle and Float
135
Install Float Assembly
135
Inspect Float Setting
136
Install Main Nozzle and Jet
136
Installing Carburetor Nozzle and Main Jet, High Altitude Compensation
136
Installing Bowl
136
Installing Carburetor Spacer
137
Carburetor Intake Elbow
137
Carburetor Installation
137
Carburetor Adjustment
137
Service Carburetor - 13 H.p. (Walbro Carburetor)
138
Adjusting Idle Mixture and Speed
138
Installing Idle Mixture Screw, Limiter Cap
138
Outside View, Carburetor - Typical
138
Choke Shaft
139
Removing Throttle Shaft
139
Disassemble Carburetor
139
Remove Carburetor - 13 H.P. Engine
139
Assemble Carburetor
140
Remove Fuel Inlet Seat
140
Clean and Inspect Carburetor
140
Install Welch Plug
140
Install Fuel Inlet Seat
141
Install Choke Shaft
141
Install Throttle Shaft
141
Install Main Nozzle
141
Install Idle Screw
142
Install Inlet Needle Valve and Float
142
Main Jets
142
Fuel Pump Removal
143
Installing Limiter Cap
143
Remove Fuel and Vacuum Line
143
Fuel Pump
143
Inline Fuel Filter Service
144
Fuel Pump Installation
144
Inspect Fuel Tank
144
Fuel Tank Removal
144
Magnetron Ignition
145
Ignition System
145
Spark Plug Maintenance
145
Check Ignition
145
Removing Spark Plug Elbow
146
Removing Ignition Armature, Typical
146
New Style Flywheel Puller
146
Pulling Flywheel, Typical
146
Oil Sensor Wiring
147
Install Magnetron Armature
147
Torquing Flywheel, Typical
147
Install Flywheel
147
Spark Plug Wire Routing
148
Wire Routing, Typical
148
Installing Spark Plug Elbow
148
Installing Armature
148
Install Fan Housing
149
Magnet under Armature
149
Engine Ground Wire
149
Installing Oil Gard Bracket, Typical
149
Engine Removal and Installation
150
Breather Hose Removal
150
Remove Fuel Line at Carburetor
150
Remove Engine Ground Lead
150
Engine Mount Bolts
151
Installing Clamping Tool
152
Compression Testing
152
Engine Alignment
152
Setting Tester
153
Cylinder Head
153
Pre-Setting Regulator
153
Prepare Cylinder Head for Removal
153
Removing Valve Cover, Typical
154
Removing Cylinder Head, Typical
154
Removing Rocker Nuts, Typical
154
Removing Rocker Arm Shaft
154
Valve Guide Service
155
Valve Service
155
Removing Valves
155
Valve and Seat Dimensions
155
Installing Push Rod Guide and Studs
156
Torque Pattern, Cylinder Heads
156
Installing Rocker Balls and Screws, Typical
156
Install Rocker Arm Shaft - 13 H.P. Engines
157
Adjusting Valve Clearance
157
Install Rocker Arms - 9 H.P. Engines
157
Adjust Valve Clearance - 9 and 13 H.P. Engines
157
Install Valve Cover
158
Valve Cover Torque Sequence, Typical
158
Valve Seat Width
158
Rocker Arm Stud or Shaft Torque
158
Remove Breather (Valve Cover)
159
Check Breather (Valve Cover)
159
Lubrication System
159
Breathers
159
Optional Oil Gard Systems
160
Oil Dipper Lubrication
160
Oil Dipper Inspection
160
Principles of Operation
160
Engine Starts, and Dies, or will Not Start
161
Disassemble OIL GARD Low Oil Warning System
161
Inspect OIL GARD Low Oil Warning System
161
Assemble OIL GARD Low Oil Warning System
161
Inspect Piston Ring Groove Wear
162
Remove Connecting Rod and Piston Pin
162
Pistons, Rings, and Connecting Rods
162
Inspect Connecting Rod
163
Inspect Piston Pin and Piston Pin Bore
163
Assemble Piston and Connecting Rod
163
Inspect Piston Ring End Gap
163
Install Connecting Rod and Piston
164
Ring Compressor
164
Installing Piston Assembly
164
Rod and Cap Alignment
164
Connecting Rod Screw Torque
165
Crankshafts & Cam Gears
165
Piston Pin & Piston Pin Bore Reject Size
165
Connecting Rod Reject Sizes
165
Inspect Crankshaft
166
Check Cam Gear
166
Polish Crankshaft Journals
166
Install Crankshaft
166
Cam Gear Reject Sizes
167
Check Crankshaft End Play
167
Adjust Crankshaft End Play
167
Install Crankcase Cover
167
Cylinders
168
Checking Cylinder Bore
168
To Set up for Honing
168
Resizing
168
To Hone Cylinder
169
Cylinder Finish (Cross Hatch)
169
Honing Set-Up, Example
169
Cylinder Hones
169
Cross Hatch
170
Cylinder Cleaning
170
Check Ball Bearings
170
Check Cam Gear Bearings
170
Install Magneto Ball Bearing - 9 H.P. Engines
171
Remove PTO Ball Bearing - 9 H.P. Engines
171
Install PTO Ball Bearing - 9 H.P. Engines
171
Installing Bearing - Mag. Side
171
Removing Bearing - Mag. Side
172
Installing Bearing - PTO Side
172
Remove Magneto Ball Bearing - 13 H.P. Engines
172
Bearing Removal Tool Components
173
Removing Bearing - PTO Side
173
Bearing Installation Tools Components
173
Bearing Removal Tools Components
173
Oil Seals
174
Crankcase Cover
174
Removing Ball Bearing
174
Specification Tables
175
Standard Bore
175
Remove Rotating Counterweight Shaft
175
Exhaust System
176
Inspect Counterweight Shaft
176
Install Rotating Counterweight Shaft
176
Removal of Exhaust System
176
Engine Exhaust Pipe
177
Remove Worm Gear Clamps
177
Remove Choke Cable from Muffler
177
Installation of Exhaust System
177
Electrical Systems & Components
183
Gas Vehicle Electrical System & Components
186
Micro Switches
186
Accelerator Micro Switch
186
Gas Vehicle Schematic
186
Gas Vehicle Key Switch
187
Console Shifter Micro Switch Adjustment
187
Adjust Micro Switch Position
187
Electrical System Testing
188
Vehicle “Clicks”, but Starter Does Not Spin Engine
188
Vehicle will Not Click or Spin Engine to Start (Forward or Reverse)
189
Vehicle Operates in Forward Only, Not in Reverse
190
Vehicle Operates in Reverse Only, Not in Forward
190
Reverse Alarm Operates in Forward and Reverse
191
Charging Circuit Test
192
Voltage Regulator
192
Engine Kill Circuit
192
Diode Testing
192
Voltage Regulator Removal
193
Voltage Regulator Installation
193
Starter/Generator
193
Starter-Generator
194
Holding Brushes off Commutator
194
Removing Armature Bearings
194
Inspecting Brushes
195
Minimum Brush Length
195
Brush Springs
195
Armature Inspection
195
Armature Ground Test
196
Armature Short Test
196
Armature Coil Balance Test
196
Open Field Test
197
Refinishing Commutator
197
Grounded Field Test
197
Field Coil Inspection
197
Battery, Gasoline Vehicle
199
Antidote
199
Visual Inspection and Maintenance
199
Load Testing
200
Storage
200
Battery Removal
200
Electric Vehicle Electrical Systems and Components
201
Electric Vehicle Battery
201
Minimum Voltage (12 Volt Batteries)
201
Conditions Which Affect Charging
202
Battery Electrolyte Level
202
Testing Battery
203
Specific Gravity Test
203
Using the Hydrometer
203
Preparation for Discharge Test
204
Interpretation of Discharge Test Results
204
Discharge (Load) Test
204
Interpretation of Hydrometer Readings
204
Key Switch
205
Storing Batteries
205
Solenoid
206
Motor Resistor
206
Speed Switch (Pot Box)
206
Key Switch Test (Electric Vehicles)
206
Speed Switch Assembly
207
Pot Switch Test
207
Micro Switch Test
207
Pot Switch Wires
208
Pot Switch Adjustment
208
Traction Motor
209
Speed Switch Assembly Adjustment
209
External Motor Inspection
209
Internal Motor Inspection
210
Motor Disassembly
210
Remove Armature
210
Shorted Armature Test
211
Armature Testing
211
Brush Removal
211
Growler Test of Armature
212
Brushes
212
Bearings
212
Frame & Field Coil
213
Terminal Assembly and Torque
213
Press Bearing and End Cover on to Armature
214
Motor Installation
214
Torque Motor Terminals
214
Check Speed Control Adjustment
215
Adjust Speed Control
215
Electrical Operation and Circuits
215
XP Speed Control System (Soft Start System)
215
Second Speed
216
Third Speed
216
Reverse
216
Trouble Shooting Guide - XP Speed Control System
217
Vehicle Does Not Operate, Forward or Reverse.
217
No Second and Fourth Speed, Operates Correctly in First and Third
218
Vehicle Does Not Operate in Reverse, Operates Correctly in Forward
218
No First and Third Speed, Operates Correctly in Second and Fourth
218
No First and Second Speed, Operates Correctly in Third and Fourth.
218
No Third and Fourth Speed, Operates Correctly in First and Second
219
No Fourth Speed, Operates Correctly in First, Second, and Third
219
Vehicle Continues to Operate, Accelerator Released
219
Vehicle Continues to Operate, Key Switch and off Position
219
XP Speed Control Wire Diagram
220
XP Plus System (Curtis System)
221
Speed Control Switch (Pot Box)
221
Trouble Shooting Guide - XP Plus Speed Control System
222
XP Plus Speed Control Wire Diagram
226
Power Master System
227
Power Master System Testing
228
Test Voltage at Harness Plug
228
Speed and Directional Circuit Testing
229
Power Master System Wiring Diagram
234
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Columbia ParCar P4E Specifications
General
Model
P4E
Category
Golf Cars
Power Source
Electric
Seating Capacity
4
Battery Voltage
48V
Battery Type
Lead-Acid
Charger Type
Onboard
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