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Journeyman Series
Columbia Journeyman Series User Manual
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Maintenance Manual
2
Table of Contents
Default Chapter
3
Table of Contents
3
Chapter 1 Overview
9
Preparation for Emergency
9
Safe Use of Battery
9
Safe Use of Lubricating Oil
9
Safety Precautions
9
Electrical Safety During Maintenance
10
Use the Designated Lifting Jack
13
Cautions
14
Washing and Cleaning
14
Keep Tidy
14
Tightening Torque
15
Parts Replacement
15
Washer, Grease Fitting and O-Ring
15
Bearing and Oil Seal
15
Recommendations on Disassembly and Assembly
15
Use Appropriate Tools
14
Special Tools
14
Instrumentation for Electric Control System
14
Chapter 2 Regular Inspection and Adjustment
16
Regular Maintenance
16
Periodic Lubrication Plan
18
Braking System
19
Inspection of Brake Drum and Brake Shoe
21
Inspection of the Accelerator Pedal
24
Inspection of the Steering System
24
Inspection of the Steering Linkage
25
Inspection of Stub Axle
26
Inspection of the Front Wheel Alignment
26
Inspection of Tires and Wheel Rim
27
Inspection of the Front Wheel Bearing
28
Inspection of the Rear Axle Bearing
28
Inspection of the Shock Damper
29
Inspection of the Seat Belt
30
Chapter 3 Canopy
31
Removal of Canopy Rods
31
Install
32
Removal of the Canopy
31
Remove
31
Install
31
Removal of the Pillar
32
Remove
32
Install
33
Chapter 4 Body
34
Remove
34
Removal of the Front Bumper
34
Removal of the Rear Bumper
34
Install
34
Removal of the Rear Tray
34
Removal of the Seat Cushion
35
Remove
35
Install
35
Removal of Front Cover
37
Remove
37
Install
37
Removal of the Dashboard
38
Remove
38
Install
39
Removal of the Rear Cover
39
Remove
39
Install
40
Rear Cover
41
Chapter 5 Front Axle
42
Front Axle
42
Removal of the Front Axle
43
Remove
43
Inspect
47
Install
48
Driving Axle
49
Chapter 6 Driving Axle
50
Remove
50
Inspect and Test
53
Install
54
Removal of the Driving Axle
50
Gearbox
56
Removal of the Differential Gear
57
Remove
57
Inspection
59
Install
59
Chapter 7 Brake System
60
Accelerator Pedal
62
Brake System
62
Chapter 8 Steering System
63
Steering System
63
Removal of the Steering System
65
Removal of the Steering Gear
66
Disassembly of the Steering Gear
67
Install
70
Electrical Power Steering System
71
Removal of ECU (Electrical Control Unit)
72
Removal of EPS Assy from Frame Body
73
Disaseembly of EPS Assy
74
Install
74
Electric Schenatic Diagram(Include EPS System)
75
Chapter 9 Electric Component
76
Key Switch Removal
76
Key Switch Installation
79
Removal of Forward/Reverse Switch
80
Installation of Forward/Reverse Switch
80
Horn Removal
82
Horn Installation
83
Combination Switch Removal
83
Combination Switch Installation
85
Controller Removal
85
Controller Installation
88
Charger Receptacle Removal
89
Charger Receptacle Installation
89
Battery Removal
89
Battery Installation
90
DC Converter Removal
90
DC Converter Installation
91
Motor Removal
92
Motor Installation
94
Removal of Bulb of Headlight and Front Turn Signal Light
94
Headlight Installation
94
Tail Light Removal
95
Tail Light Installation
95
High Mount Stop Lamp Removal
95
High Mount Stop Lamp Disassembly
96
High Mount Stop Lamp Installation
96
Wiper Removal
96
Chapter 10 Troubleshooting
98
Troubleshooting Instructions Part 1
98
Check Procedures
100
Index for Check Procedures
100
Check Procedure 1-Battery / Voltage Check
101
Check Procedure 2--Accelerator Signal Voltage
101
Check Procedure 3-- Motor Voltage at U V W
101
Check Procedure 4 - E-Brake Switch
102
Check Procedure 5-Battery Voltage
102
Check Procedure 6-Circuit Check for Key Switch and Accelerator Pedal Switch
102
Check Procedure 7--Controller Signal
104
Check Procedure 7A-Pin 1
105
Check Procedure 7B-Pin 2 and 24
106
Check Procedure 7C-Pin 3 and 4
106
Check Procedure 7 F -- Pin 11
107
Check Procedure 7D-Pin 7 and 8
107
Check Procedure 7E-Pin 9
107
Check Procedure 7E-Pin 15 and 26
108
Check Procedure 7G-Pin 13
108
Check Procedure 8-Motor Speed Sensor
108
Check Procedure 10-Reverse Buzzer
109
Check Procedure 9-Forward/R Everse Switch
109
Check Procedure 11 -- Battery Discharge Meter
110
Check Procedure 12-- High Mount Stop Lamp
111
Check Procedure 13 - Wiper
111
Troubleshooting Instructions Part 2
112
Battery
117
Chapter 11 Battery and Charger
117
Overview
117
Common Misconceptions about Battery
118
Battery Replacement
119
Battery Maintenance
120
Preventative Maintenance
120
Electrolyte Liquid Level
121
Self Discharge
121
Vibration Damage
122
AC Power Supply Line
123
Battery Charging
123
Deep Discharge
123
Premature Excessive Discharge
123
Alternating Use of Vehicles
124
Electric Vehicle and Charger Numbering
124
Battery Troubleshooting Diagram
125
Charging Voltage Inspection
126
Inspection and Test of the Battery
126
Inspection and Test of the Battery Charger
126
Inspection with Hydrometer
126
Calibration of Hydrometer
127
Hydrometer Inspection Result Presentation
127
Procedures for Inspection with Hydrometer
127
Discharge Test
128
Discharge Test Result Presentation
129
Procedures for Discharge Test
129
Battery Troubleshooting Example
130
Battery Storage
131
Battery Charger
132
Conditions to be Noted before Charging
132
Overview
132
Get to Know the Charger
133
Removal of the Charger
134
Troubleshooting
138
On-Board Charger
139
Operating Instructions
139
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Columbia Journeyman Series Specifications
General
Brand
Columbia
Model
Journeyman Series
Category
Electric Vehicles
Language
English
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