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Chapter 2 - Columbia ParCar Corp.

1. 12 Volt Negative Source Potbox f g 6K O 0 6 nere pes dois M TY i Resistor i h Mem NN COLOR CODE R RED LL ORANGE qa LE Ug Y YELLOW W WHITE BE BLUE M BK BLACK Qaz All Unspecified L Cables are Black Figure 1 Wiring Diagram Speed Switch Assembly This type of speed switch assembly is used with XP plus system to signal the speed control module regarding accelerator pedal position The speed switch assembly consists of two separate circuits First is the accelerated micro switch This switch activates the vehicles electrical system as the accelerator is depressed As the accelerated 1s released this switch disables the vehicles electrical system for safety and to conserve energy The second circuit is a variable resistor commonly referred to as a pot or potentiometer The potentiometer is a variable resistor used to signal the speed control module regarding accelerated pedal position Testing Testing can be performed on or off of vehicle To determine if speed switch is functioning correctly follow precisely testing instructions in the order as they appear As discussed before the speed switch assembly uses two separate circuits Test each circuit to ensure that both components are in proper working order Micro Switch Test l Using a digital volt ohm meter VOM set to test continuity probe to the f
2. Color Code R RED O ORANGE Y YELLOW W WHITE BE BLUE BK BLACK GY GRAY Unspecified Cables are Black 4 22 M18 Electrical Wiring BC3 30 BC4 25 BC3 30XB BC4 25XB M18 Electrical Wiring BC3 30 BC4 25 BC3 30XB BC4 25XB m Description Module Speed Controller 36 48V 275 AMP Module Speed Controller 36 48V 400 AMP Optional 7 6 70061 00A Switch Speed 9Pot Box 7 1 8011 97 Switch Micro 4886 02 Diode Set With Connectors 7 74865 02 Diode Only 6 9823 00 Solenoid Double 12V Coil Forward Reverse N 7454 02 Solenoid Single12V Coil Main 71408 96 Alarm Reverse 9 48V 71730 01 Keyswitch Universal 1731 01 Keys Only 66014 84 7 66014 84 Battery Deep Cycle 6V T 105 220Ah Battery Deep Cycle 6V T 145 244Ah Battery Deep Cycle 8V Fuse Poly Auto Reset Resistor Assembly Motor Traction 36 48V 6 7 5 7 6 S Harness Wiring Control Panel 7 6 7 E 7 7 lt o M Harness Wiring Main Harness Wiring 12V Accessory Cable 4 Gage 37 1 2 Length Cable 6 Gage 20 Length Meter BDI 48V ENM Meter BDI 36V ENM 7 75033 91 Meter Hour 10 80 VDC 708056 Switch Seat Located in Seat Cushion Assy 14953 176176 Button Horn Horn 12V Headlight Taillight Round 4 Switch Turn Signal Switch Headlight Charger Built in 36V 25 AMP 115V 60Hz Charger Built in 48V 120V 60Hz Receptacle AC Built in Charger Cord E
3. AutoRest Circuit Breaker 5 19 COLUMBIA xx Industrial amp Commercial Vehicles 350 N Dewey P O Box 30 Reedsburg WI 53959 Phone 608 524 8888 Toll Free 800 222 GOLF 4653 Fax 608 524 8380 Web www parcar com E Mail techsupport 2parcar com infoparcar parcar com
4. Operational Safeguards Study controls and be familiar with their function before operating vehicle Allow only authorized and trained personnel to operate vehicle Remain seated with seat belts fastened if so equipped when vehicle is in operation Allow only one occupant per seat DO NOT carry any other persons on the vehicle unless vehicle is designed and equipped for such purpose Keep arms legs and feet inside vehicle at all times when vehicle is moving Keep a clear view of the path of travel Observe general traffic laws and maintain a safe clearance Signal turns and stops far in advance of intended action Keep vehicle clear of hazardous or explosive locations Drive slowly when making turns Drive slowly and straight on up and down slopes DO NOT make turns on steep hills or inclines Maintain a safe distance from the edge of ramps and platforms Vehicle Operating Instructions Set parking brake before leaving vehicle and also remove key when vehicle is unattended Block wheels of vehicle if left on an incline Driving The Vehicle Fasten seat belts if vehicle is so equipped Insert key in switch depress brake pedal firmly and turn key to ON position Switch electric shift switch to the direction of desired travel Release the parking brake and brake pedal Slowly depress accelerator pedal to obtain desired vehicle speed To slow or stop vehicle remove foo
5. d Always cover or cap brake fluid containers when not actually dispensing the fluid If containers are left open or uncovered the fluid absorbs moisture from the air e Never reuse old brake fluid drained from hydraulic system Used brake fluid is contaminated to some extent f Store brake fluid containers in a clean dry place A CAUTION Before bleeding the hydraulic system the cause of the problem should be diagnosed and properly repaired If you find it necessary to bleed the brake system for any reason check the fluid level in the master cylinder and add fluid as required Use DOT 3 fluid only A CAUTION Do not allow fluid to get on brake pads rotors Bleeding The Hydraulic System A WARNING Brake fluid can cause irritation of eyes and skin and may be harmful if swallowed If fluid 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 flush with plenty of water Get medical attention for eyes KEEP BRAKE FLUID OUT OF THE REACH OF CHILDREN 1 line or cylinder has been opened when servicing brake system or when satisfactory brake adjustment is unobtainable or pedal is spongy bleed air from hydraulic system as follows 2 Insert the end of a length of appropriate size plastic tubing over wheel cylinder bleeder nipple located next to wheel cylinder line connection 3 Place the other end in any clear glass jar con
6. COLUMBIA s Industrial amp Commercial Vehicles Burden Carriers BC3 21 to BC4 45XB Operation and Maintenance Manual With Illustrated Parts List 11 02 99486 01 COLUMBIA Industrial amp Commercial Vehicles Dear Owner Congratulations on your purchase of Columbia Industrial amp Commercial Vehicle Model Burden Carrier At Columbia Industrial amp Commercial Vehicle we pride ourselves on manufacturing electric personnel and burden carriers that are second to none in terms of designs quality of materials and workmanship While our vehicles are designed and built for maximum efficiency durability performance and safety proper maintenance and operator knowledge will nevertheless play a vital role in your long term product satisfaction Thus the information in this manual should be closely read studied and understood prior to operating your vehicle If you do not clearly understand any portion of this manual see your authorized Columbia Industrial amp Commercial Vehicle Dealer for clarification The manual contains the most current information available at the time of publication However as our Research and Engineering Department continually work to improve our products It is possible that models produced subsequent to the publication of the manual may include improvements that are not referenced in this manual Our Dealers can advise you of any updating of our recommended service and maintenance procedures that
7. Forward or Reverse Check Wire Connection Speed Control Unit Vehicle Will Move Only Forward Toggle Switch Forward Solenoid Vehicle Will Move Only Reverse Toggle Switch Reverse Solenoid If these test procedures do not resolve your vehicle problem contact your Columbia Industrial Vehicle Dealer for service See page 5 9 for Electrical Schematic Diagram 5 2 XP Plus System Curtis System Operation The XP Plus speed control system offers infinitely variable speed control in forward and in reverse This is a highly efficient speed control system in that the pulse modulating controller does not waste battery energy For reduced speeds the controller turns on and off the motor circuit at an extremely high rate of speed For increased speed the controller increases the duration at which the motor circuit is completed then decreases the connection duration for lower vehicle speed The result is a smooth and gradual increase and decrease in speed appropriate to accelerator position This system also uses a potentiometer pot box for accelerator speed control Two six 6 terminal solenoids are used for directional control one four 4 terminal solenoid is used as a main contactor Speed Control Switch Pot Box For details regarding speed control pot box adjustment or repair refer to page 5 14 This section contains information regarding testing and failure diagnosis Warning Raise vehicle per lifting instructions Chapter
8. Verify fenders are attached properly not bent out or are not protruding 2 Consider what affect the problem has on the safe operation of the vehicle fthe safe operation of the vehicle is affected remove the vehicle from service until the problem has been corrected Report the problem to the individual s responsible for correction and or repair If the safe operation of the vehicle is not affected record the problem and report it to the individual s responsible for correction and or repair 3 Report any service issue problems to the individual s responsible for correction and or repair or contact your local Columbia Industrial Vehicle Dealer for service A DANGER If any problems are found DO NOT operate vehicle until repairs are made Failure to make necessary repairs could result in fire severe personal injury property damage or death Consult your local Columbia ParCar Dealer for professional service 1 8 Lifting Instructions A WARNING Use extreme caution lifting or working on or around lifted vehicle Vehicle should be lifted only when on a flat hard and level surface When lifting the vehicle for service use a sturdy lifting device such as a hoist floor jack or hydraulic lift ALWAYS block wheels and set parking brake of the vehicle to keep it from rolling When using a lifting device lift only on sturdy underbody parts an example being the frame When using a floor jack lift only on sturdy underbody parts
9. Jack stands need to be of sufficient load capacity to hold the full listed weight capacity from the vehicle description and specifications section A WARNING DO NOT work under your vehicle unless it is firmly secured on jack stands Unibody Jack Stands Figure 6 Jack stands under vehicle Chapter 2 OPERATOR INFORMATION SAFETY INSTRUCTIONS Rules amp Guidelines Driver Training Program Driver Qualification SAFETY COMMITTEE VEHICLE OPERATING CONTROLS VEHICLE OPERATING INSTRUCTIONS Pre Operations Checklist Operational Safeguards Driving the Vehicle VEHICLE STORAGE Storage Preparation for Storage Returning Vehicle to Service 2 a PAGE 2 2 2 3 2 4 2 7 Operator Safety Instructions NOTE It is the responsibility of the owner of this vehicle to assure that the operator understands the various controls and operating characteristics of this vehicle as well as obeying the following safety rules and guidelines extracted from the American National Standar ds Institute personnel and burden carriers ANSI B56 8 WARNING This vehicle is not designed to be driven on public highways The Burden Carrier travels on level surfaces at a maximum rated speed of 8 5 mph DO NOT exceed this speed Exceeding this speed may result in steering difficulty motor damage and or loss of control Safety Rules amp Guidelines This vehicle is designed to be driven over smooth surfaces in and around places such as w
10. RE E 4 9 Differential Assembly Assembly Differential Item Part Description Differential Axle Bearing Retainer Bearing Axle Retainer Ring Bearing Supplied with Bearings 82507 00 Gasket Plate To Housing Not required for 10 Wheel 6 Housing Axle Locknut 3 8 16 Axle Bearing Retainer to Housing 9 Shim Supplied with Center Section Ring Pinion Drive Supplied with Center Section Bearing Pinion Race Pinion Bearing 14 Retainer Pinion Supplied with Center Section Sleeve Seal Pinion Flange Sprocket 18 Nut Sprocket Flange Supplied with Center Section Rotor Inner Oil amp Grease Seal Z N gt 2 gt lt P z Mine gt 1 o 4 10 Front Rotor Hub Wheels amp Tires Tem Para Description 4 2 R Hub Kit Assembly 4 9028 _ Cup Bearing Ra 5 9087 Cone Bearing 1 0 O 6 12000 Seal Hub gt 0 0 00 0 y O 7 6038 Washer Bearing Retainer 1 8 7510 Nut Spindle 1 14 40 O 9 561 Pin Cotter Cover Dust Nut Lug 1 2 20 Wheel amp Tire 18 5 70 500 x 8 Range Kit Wheel amp Tire 18 8 50 x 8 Range B Tire amp Wheel Assy Solid Tire Lug Tread Optional Kit Front Brakes Caliper Left Front For Front Wheel Brake Option Only Caliper Right
11. after they have been rolled out onto an appropriate battery transfer stand charges the batteries 1 Besure the battery stand is in place before starting to roll the battery rack out of the vehicle 2 Pullthe rack out far enough so the large disconnect plug swings into view BATTERIES amp ELECTRICAL 3 Continue to pull the battery rack onto the stand The disconnect plug will automatically be pulled apart by the momentum of the rack A Caution DO NOT use anything to pry the two halves apart The plug can be broken or a short can result from trying to pry the plug apart 4 Plug the charger cords into the battery pack and the charger into an AC outlet at the designated charging station There may also be a separate manual which accompanied the charger when delivered with any portable charger you receive Refer to the charger manual for additional information Lamps Fuse and Flasher Fuses Located Under The Seat Board Main 12v 30 Amp Neg 69702 00 Auxiliary 10 Amp Circuits 69717 00 r5 75 slasher Hazard amp Turn Signal Flasher 71975 87 DRIVE SYSTEM Drive Chain Adjustment 1 Remove chain cover 2 Loosen the 4 motor mounting bolts slightly see Figure 5 3 Rotate adjuster cam counterclockwise until chain is correctly tensioned see Figure 4 The chain should deflect 1 8 to 3 16 when pressed down at the middle of the span see Figure 4 4 Tighten motor mounting bolts and re check chai
12. may have transpired subsequent to your purchase Should you have questions or encounter problems which our Dealer is unable to answer or resolve we encourage you to contact us at the address below Columbia ParCar Corp 350 N Dewey Avenue P O Box 30 Reedsburg WI 53959 Phone 608 524 8888 Fax 608 524 8380 800 222 4653 Web www parcar com E Mail info parcar com Your decision to invest in a Columbia Industrial amp Commercial Vehicle is very gratifying to us and we wish you many years of satisfaction Columbia ParCar Corp A member of the Nordic Group of Companies 350 Dewey Avenue 30 Reedsburg WI 53959 Phone 800 222 4653 or 608 524 8888 e Fax 608 524 8380 Visit us on the web www parcar com FOREWORD This service manual has been prepared with two purposes in mind First it will introduce the trained maintenance professional to the latest field tested and factory approved major repair methods Secondly it will acquaint the reader with the construction of Columbia Industrial amp Commercial vehicles and assist him her in performing basic maintenance and repair We sincerely believe that this manual will make your association with Columbia Industrial amp Commercial Vehicles more pleasant and profitable In addition to the information given in this Operation Maintenance Service and Parts Manual Service Bulletins are issued to Columbia Industrial amp Commercial Vehicle Dealers from
13. micro switch circuit defective Full battery voltage diodes between forward and reverse solenoid defective Less than full battery voltage diodes between forward and reverse solenoids defective or Vehicle Does Not Operate In Forward Operates Correctly in Reverse accelerator micro switch defective Key switch in forward depress accelerator pedal Voltmeter Full battery Less than full battery voltage positive red lead to white wire at 1 tab terminal of speed voltage 2 Good diodes between forward and control module Voltmeter negative black lead to controller B reverse solenoids or terminal accelerator micro switch defective Key switch in forward depress accelerator pedal Voltmeter Full battery If low or no voltage check positive red lead to controller B terminal Voltmeter voltage 2 Good cables and cable connections negative black lead to 1 terminal at forward solenoid from controller M to forward solenoid 1 terminal Key switch in forward depress accelerator pedal Voltmeter Full battery If low or no voltage replace positive red lead to controller B terminal Voltmeter voltage 2 Good defective forward solenoid negative black lead to 2 terminal at forward solenoid Key switch in forward depress accelerator pedal Voltmeter Full battery If low or no voltage check positive red lead to controller B terminal Voltmeter voltage Good cables and cable connections negative black lead to 3 terminal of r
14. motor damage and loss of vehicle control See Vehicle Specifications Table on page 1 7 for vehicle rated capacity The vehicle identification label will indicate model and rated capacity Do not exceed this rated capacity This rated capacity includes optional equipment cargo passenger and driver This vehicle conforms to requirements for Type E vehicles as described in O S H A Standard Section 1910 178 Powered Industrial Trucks and with all applicable portions of the American National Standard for Personnel and Burden Carriers ANSI B56 8 1993 Part III To insure prompt service when repairs or adjustments are required your Columbia Industrial Vehicle Dealer must have the following information For your own personal reference fill in the space provided below VIN The VIN Nameplate attached to the dashboard near the steering column indicates the power system model code designation and factory modifications options For security reasons the serial number is also stamped on the left square frame tube under the driver s seat A CAUTION Do not remove any nameplate warnings or instructions affixed to your Columbia Industrial Vehicle COLUMBIA SX Electric Utility Vehicle Information Vehicle Identification Number V I N 4KK 12345 Rated Capacity Including Passengers and Operator 3000165 1362kg Operating Weight 1604 Ibs 728kg Without Batteries 1224 Ibs 556kg Maximum Service Weight of Batteries
15. 2 Support safely on jack stands before proceeding Failure to do so could cause accident and or injury Electrical Operation and Circuits Charging Keep switch Off Accelerator speed switch position Up At rest SolenoId E or ete Not energized connection between bottom terminals top terminals open Solenoid eoe Not energized connection between bottom terminals top terminals open Solenoid Not energized large terminals open Controller 1 tab terminal Not energized Forward Operation Key switch position forward Accelerator pedal depressed Solenoid F eee Energized connection between large top terminals large bottom terminals open Solenoid R ac seh ett trs Not energized contact between large bottom terminals large terminals open Solenoid M teet Energized contact between large top terminals Controller 1 tab terminal Energized Reverse Operation Key switch position reverse Accelerator pedal depressed Solenoid E Not energized contact between large bottom terminals large top terminals open Solenoid Energized connection between large top terminals large bottom terminals open Solenoid M Energized contact between large terminals Controller 1 tab terminal Energized Trouble
16. 380 Ibs 173kg This Carrier is Designed for 36 V Normal Designed To Conform With The Mandatory Requirements Of ASME ANSI B56 8 Part III ANSI UL 583 Type E and OSHA 1910 178 Reedsburg WI USA Figure 4 VIN Name Plate KIZA Figure 5 Vehicle Identification Nameplate VIN Number Locations VIN Matrix SEQUENTIAL SUFFIX VIN PREFIX FOUR CHARACTER SYSTEM SERIAL WHEN USED NUMBER 1st Character 2 Character 3 amp 4 when used Five Numeric SP when used Power System Model Code Factory Characters indicates this is a Designation Modifications Special Vehicle Options having been 4 XP Power 12345 significantly System 62 inch bed System 8 6V batteries modified from the K Budden Carrier E 48 volt Power model indicated by X 4 wheel hydraulic disc brakes Y Rear wheel hydraulic disc brakes K 3000 36 volt or critical when ordering parts for any vehicle with an SP prefix to give the 1800 48 volt entire VIN number to N 4000 36 volt or customer service to ensure correct service O 5000 36 volt or parts are ordered and Burden Carrier Vehicle Specifications Vehicle Specification Table voltage Capacity Capacity Speed Note All burden carriers are built to carry 2 people only and cargo BC3 21XB 36 Volts 4500 165 14000 Ibs 14 0 mph Upon Delivery of your Burden Carrier Note This vehicle should be inspected immediately after delivery Use the following guidelines
17. 7 Remove the motor mounting bolts and lift the motor out of vehicle BATTERIES Battery Care Electric Vehicle Battery The storage battery receives stores and delivers electrical power This receiving storing and delivering of electrical power is called a cycle Receive Charging vehicle batteries Store Vehicle standing idle Deliver Driving vehicle The type of battery used in a Columbia Industrial amp Commercial Vehicle has a service requirement which is quite different from that of an automotive battery BATTERIES cont The electric vehicle battery supplies all of the power to drive the vehicle and during operation the power stored in the batteries is expended While the amperage drain rate can vary greatly depending on the type of service the duration of use and the number of starts and stops made during a day the batteries nevertheless progress through each duty cycle from fully charged to an almost depleted state This type of service is known as deep cycle service and electric vehicle batteries are specifically designed to handle this type of service Proper performance of your Columbia Industrial Vehicle can only be obtained from specified deep cycle electric vehicle batteries A CAUTION Automotive batteries should never be used for deep cycle application as their useful life will be very short A CAUTION Use extreme caution when working on or near batteries Gases escaping from charging b
18. Amp _ Module Speed Controller 36 48 Volt 400 Amp _ Speed Switch Pot Box Micro Switch Diode Set With Connectors l aM l l l movo Diode Only 1459 87 Solenoid 6T 36 V 1458 87 Solenoid 4T 36 V 7 71457 99 Solenoid 6T 48 V 7 71456 99 Solenoid 4T 48 V Charger built in 36V 25 AMP 115V 60Hz Charger built in 48V 120V 60Hz Charger built in 36V W Plug and Ammeter on panel AC Receptacle Charger Built in Cord Extension Buzzer Round Reverse 9 48 Volt Meter BDI 36V Meter BDI 48V Hom 12 Volt Key Switch with Key Key Only Keyswitch Universal Switch Forward Reverse 6 6 a 6014 84 Battery 6 Volt Deep Cycle T105 220Ah 6016 96 Battery 6 Volt Deep Cycle T 145 244 Ah D 11 a oo Battery 8 Volt Resistor Assembly Head Light Motor Traction 36V Motor Traction 48V Seat Switch Integral Part of LH Seat PN 51701 00 Taillight Round 4 Switch Light Block Fuse Fuse 10 Amp 6 9702 00 Fuse 30 Amp 66324 00 Battery Hold Down 71807 80 Button Horn Not Pictured in Illustration Wet Cell Sold As Is Only Pick up or Will Call ONLY gt gt EE NL EN E M Em a RECS 4 21 Speed Control cont Electrical Shift Switch Connection ww e e e e e of FWD N REV Reverse o 12 Volt Negative Source
19. ON LA 6 zm ae ui RUE E NEN Mount RH Axle Mount Bracket Accelerator Linkage Accelerator 2339 Screw 10 24 x 34 Washer 10 Plain Type A Rod Connecting To Pot Box Pedal Accelerator Assembly Spring Extension Bushing Locknut Nylok 10 24 2592 Screw Pan Head 10 24 x 1 2 4 26 Options Cargo Retainer Description 51380 00 Kit Cargo Retainer 12 S lt 51381 00 Kit Cargo Retainer 12 51382 00 Assembly Side Panel 51383 00 Assembly Side Panel DN e 8 cE fete betel H a Assembly End Panel 3 Stake Pocket Bolt 1 4 20 x5 8 Lockwasher 1 4 Nut 1 4 20 Deckboard Short Deckboard Long 1 Options cont Hem Part Oy 50122 00 90123 00 90129 00 90628 00 90637 00 787 B 0368 42 0118 00 04 117 00 ZZ 4120 92 92 9 o ojojo 87 BS Bolt 5 16 18 x 3 4 Protector Panel to Cab 17 Bolt 5 16 18 x 1 Panel to Cab to Frame 52 Washer 5 16 Flat Panel to Cab to Frame 0134 00 Panel Protector Rear Cab Locknut 5 16 18 Panel to Cab to Frame 04 Washer Trim Mounting 0125 00 Assembly Door Complete LH 90124 00 0127 00 0126 00 1355 00 1353 00 92 Screw Machine 10 24 x 1 2 0132 00 11742 10653 00 3767 B 7036 B 7036 B 7688 B 61266 61276 84114 92 Wiper Arm Adjustable Option 84113 92 Wiper Blade 18 Option LH 0133 00 Trim Door Openi
20. Pivot Points With Grease Fittings Without Grease Fittings and Cab Maintenance Body Upholstery Cab Windows CHAPTER 4 ILLUSTRATED PARTS LIST Body Items Front Axle amp Suspension Rear Suspension Advanced Motor 69404 00 Direct Drive Advanced Motor 69401 00 Chain Drive Drive System Differential amp Brakes Direct Drive Drive System Sprocket Motor Chain Assembly Drive System Differential Assembly Front Rotor Hub amp Tires Brake Hydraulic Drum Brake Linkage Parking Brakes Hydraulic System Caliper Assembly Rear Caliper Assembly Front Steering Linkage Steering Gear Assembly Steering Box Steering Column Electrical System M 18 Electrical System M 18 Drive System Accelerator Linkage 3 18 3 18 Table of Contents cont Options Cargo Retainer Cab Items Hitches Battery Push Pull Kit CHAPTER 5 Electrical Troubleshooting 36 Volt Forward amp Reverse Switch Troubleshooting Guide Electrical System Troubleshooting Guide Electrical Diagram Speed Switch Testing Assembly amp Disassembly Adjustments M 18 Electrical Shooting Troubleshooting Guide Electrical Diagram 4 23 4 24 4 26 4 27 5 2 5 4 5 9 5 10 5 11 5 12 5 14 5 19 About This Manual This manual contains information to safely operate and maintain the Burden Carrier manufactured by Columbia Industrial amp Commercial Vehicles Only trained maintenance p
21. and use the maintenance checklist to determine how often you should perform each procedure Follow the guidelines below to assure proper maintenance of your Burden Carrier Allow only trained maintenance personnel to maintain repair and inspect the vehicle Before starting any repairs or maintenance immobilize the vehicle by turning the key switch off removing the key and setting the park brake Disconnect both of the main battery leads before working on or disconnecting any electrical component or wire Support the chassis with jack stands before working under a raised vehicle Conduct vehicle performance checks in an authorized area where a safe clearance exists Before starting the vehicle follow the recommended safety procedures in Chapter 2 Operator Information Avoid fire hazards and have fire protection equipment present in the work area use an open flame to check level or leakage of battery electrolyte use open fuel or flammable fluids for cleaning parts Work in a properly ventilated work area Regularly inspect and maintain in safe working condition the brakes steering mechanisms speed and directional control mechanisms warning devices guards and safety devices Inspect and maintain battery limit switches protective devices electrical conductors and connections in conformance with the manufacturer s recommended procedures Keep the vehicle in a clean condition to min
22. are fully charged or adequately charged to provide sufficient energy for duration of operations Assure the AC cord is disconnected from the vehicle Check to assure the electrolyte level in each cell covers the top of cell plates Check that batteries are free of corrosion Check for loose terminals or connections Tire Pressure Check for proper inflation keep tires inflated to the specifications labeled on the sidewall Tire size 5 70 x 8 Factory setting is 35 to 50 psi Lights amp Horn UTI mM RE CERE E EE lights on and make sure they illuminate Depresshornbuttontosoundhorn horn button to sound horn Brakes Check brake pedal for a firm pedal pressure with minimal travel Check parking brake for proper engagement and release Check for steering responsiveness and the absence of excessive free play Check to make sure cargo is secured to the bed platform C iud Check to make sure load is balanced and not top heavy Check path of intended travel for obstructions and that underside is clear Make sure driver and passenger are secured by seatbelt before moving vehicle If Equipped A CAUTION DO NOT overload the vehicle Never exceed Maximum payload as specified on the vehicle data plate Batteries A CAUTION Your safety and the safety of others depend on your safe operation and maintenance of this vehicle Prior to operation you the operator must be thoroughly familiar with this and all other sections of this manual
23. black lead to top terminal of forward solenoid Key switch in forward depress accelerator pedal Voltmeter positive red lead to controller terminal Voltmeter negative black lead to traction motor A 2 terminal Key switch in forward depress accelerator pedal Voltmeter positive red lead to A 1 terminal at traction motor Voltmeter negative black lead to A 2 terminal at traction motor As accelerator is depressed battery voltage should rise to within 1 to 2 volts of battery voltage Full battery voltage Good Full battery voltage Good Full battery voltage Good Full battery voltage Good Full battery voltage Good Full battery voltage Good Full battery voltage Good Refer to speed switch testing below before continuing If speed switch testing concludes speed switch is good then controller has failed If low or no voltage check cables and cable connections from controller M to reverse solenoid large side terminal If low or no voltage replace defective reverse solenoid Defective field coil in traction motor See Traction Motor page 3 7 for repair procedures If low or no voltage check cables and cable connections from motor S 2 terminal to forward solenoid bottom terminal Less than full battery voltage replace defective forward solenoid If low or no voltage check cables and cable connections from forward solenoid top terminal and to motor 2 If motor does no
24. switch in forward depress accelerator pedal Voltmeter positive red lead to white wire at 1 tab terminal of speed control module Voltmeter negative black lead to controller B terminal Key switch in reverse depress accelerator pedal Voltmeter positive red lead to yellow wire at reverse solenoid small terminal Voltmeter negative black lead gray wire at reverse solenoid small terminal Key switch in reverse depress accelerator pedal Voltmeter positive red lead to red wire at forward solenoid small terminal Voltmeter negative black lead to gray wire at forward solenoid small terminal Key switch in reverse depress accelerator pedal Voltmeter positive red lead to white wire at main solenoid Voltmeter negative black lead to gray wire at main solenoid Key switch in forward do not depress accelerator pedal Voltmeter positive red lead to main solenoid 2 terminal Voltmeter negative black lead to controller B terminal Full battery voltage 2 Good Full battery voltage 2 Good Full battery voltage 2 Good No Voltage Good Full battery voltage 2 Good Full battery voltage 2 Good Full battery voltage Good No Voltage Good Full battery voltage 2 Good Full battery voltage 2 Good Less than full battery voltage charge and or replace batteries Less than full battery voltage check key switch and wire harness Less than full battery voltage accelerator micro switch or micro switch circuit defecti
25. switch position 1f mount holes are slotted and torque mounting screws Route wires along frame to speed control module Connect white lead wire to 2 tab terminal and black lead wire to 3 tab terminal on speed control module See Figure 3 Tie speed switch wires along frame with wire ties to prevent wires from dragging under vehicle and damaging wires Connect red and black wires from wire harness to speed switch assembly micro switch 1st and 3rd terminals DO NOT USE CENTER TERMINAL Speed Switch Assembly Adjustment Slowly depress accelerator and check that 1 As accelerator is depressed speed switch lever does not contact micro switch plate support spacers As accelerator is released speed switch lever must contact micro switch lever shortly before accelerator pedal reaches stop position Also check at speed switch lever does not contact micro switch support spacer 5 12 If adjustment is required remove clevis pin from speed switch lever and rotate clevis to lengthen or shorten accelerator rod as required CAUTION years and models of vehicles will not be the same regarding the clevis pin position in speed switch arm If clevis pin is inserted into incorrect speed switch lever hole the following will occur Vehicle will not operate at full speed or poor hill climbing performance will be observed Move clevis pin down one hole on speed switch lever 5 Speed switch lever will contact micro switch plate
26. the risk of an electric shock connect only to properly grounded outlets Keep the charger dry Do not expose it to rain For storage keep the charger in a building 1 Connectthe AC supply cord to a properly grounded three wire outlet of the proper voltage and frequency as shown on the front of the charger Charger will start automatically in 3 to 5 seconds A CAUTION Do not leave the charger on while unattended for more than two days in a row Severe overcharging and damage to the batteries may result if the charger does not turn off 2 Monitor the ammeter for the correct charge rate The initial charge rate will vary from 14 to 22 amps depending on how much the batteries have been discharged The charge rate will taper gradually to a finish rate of 6 to 12 amps if the batteries are in good condition The charger will shut off automatically when the batteries are fully charged 3 After the charger has turned off disconnect the AC cord from the vehicle Charging Batteries Outside Vehicle for Units Equipped with Additional Battery Sets and Portable Charger CAUTION Before proceeding with battery removal check that key is off and removed from switch and all electrically operated accessories are turned off Failure to do so may cause a spark as the battery pack is disconnected igniting potentially explosive battery gases When vehicle contains optional rollout battery racks a portable charger that is plugged into the batteries
27. to make sure there are no obvious problems Inspecting the vehicle Examine the contents of all packages and accessories that may have come in separate packages with this vehicle Make sure everything listed on the packing slip is there Items should not be broken or damaged Examine any visible wiring for obvious signs of damage Check that all connections are secure Check that battery connections are tight and all cells are filled to above plates Inspect the tires for obvious wear or damage Check for proper tire inflation refer to manufactures recommendation imprinted on tire sidewall Initialfactory setting is between 35 to 50 psi Make sure that all wheel lugs are secure Check the body seats trim and other external parts for obvious damage Operate each of the following controls BEFORE turning on the key switch Accelerator Pedal for smooth operation Braking Pedal assure presence of a firm pedal with minimal travel Directional selector lever Steering check for responsiveness and little play Horn check for proper operation Each control should operate smoothly and easily without sticking or requiring undue effort What to do if you find a problem 1 If vehicle has just been delivered report any physical damage or missing items to the Shipping Company and your local Columbia Industrial Vehicle Dealer Look for body damage jagged edges etc that may cause personal injury Check for damaged or leaking batteries
28. to Body Mounting Hardware sher Chain to Latch to Body Mounting Hardware asher Latch to Body Mounting Hardware ut Latch to Body Mounting Hardware hain 15 Links sembly Latch Pin for Push Pull Kits 824 cal WARNING Disconnect Batteries 6561 90 od 5 16 18 Battery Hold Down 252 sher 5 16 Flat Battery Hold Down Mounting Hardware 680 ocknut 5 16 18 Battery Hold Down Mounting Hardware etainer Fiberglass Battery Mounting Hardware 090 oller 11 4 asher Spacer Cut 1 2 6605 00 ire Protector S 4 un 51357 00 51358 00 51362 00 51360 00 51361 00 8211 3787 B 7036 B 7688 B 51636 00 3787 B 2551 W 6031 7036 B 7688 B 5456 ZZ c P Q AR ES QN No d EA 9 ON 1 1 CHAPTER 5 Electrical Troubleshooting Forward amp Reverse 36V Electrical Troubleshooting Guide XP Electrical System Troubleshooting Guide Electrical Diagram Speed Switch Testing Disassembly amp Assembly Adjustments M 18 Electrical System Troubleshooting Guide Electrical Diagram Page 5 2 5 3 5 9 5 10 5 11 5 12 5 14 5 19 Forward amp Reverse 36 48 Volt Electric Troubleshooting Guide Appendix E TROUBLESHOOTING GUIDE Turn on Key Switch Vehicle will not move Vehicle wil Put Toggle Switch in Direction Key Switch Is on and Toggle Switch is Key Switch Direction Vehicle will Not Move Either Toggle Switch
29. to white wire at main solenoid Voltmeter negative black lead to gray wire at main solenoid Key switch in reverse depress accelerator pedal Voltmeter positive red lead to white wire at 1 tab terminal of speed control module Voltmeter negative black lead to controller B terminal Key switch in reverse depress accelerator pedal Voltmeter positive red lead to controller terminal Voltmeter negative black lead to large side terminal at reverse solenoid Key switch in reverse depress accelerator pedal Voltmeter positive red lead to controller terminal Voltmeter negative black lead to small bottomterminal at forward solenoid Key switch in reverse depress accelerator pedal Voltmeter positive red lead to controller terminal Voltmeter negative black lead to traction motor 5 1 terminal Key switch in reverse depress accelerator pedal Voltmeter positive red lead to controller B terminal Voltmeter negative black lead to small bottomterminal of reverse solenoid Key switch in reverse depress accelerator pedal Voltmeter positive red lead to controller B terminal Voltmeter negative black lead to small top terminal of reverse solenoid 5 18 voltage 2 Good Full battery voltage 2 Good Full battery voltage 2 Good No Voltage Good Full battery voltage 2 Good Full battery voltage 2 Good Full battery voltage 2 Good Full battery voltage 2 Good Full battery voltage 2 Good Full batte
30. use the leaf springs or front housing to lift the vehicle Place jack stands under the unibody at the right and left sides Then lower vehicle to allow working on the vehicle When work is completed again lift and then remove jack stands and lower vehicle to the floor Floor jack A CAUTION Before lifting ALWAYS wedge wheels and set parking brake If a floor jack is used to lift the vehicle check that the hoist is rated at a lifting capacity greater than the vehicle weight Lift the vehicle sufficiently from the floor to a 10 to 25 angle to allow the placement of jack stands to hold the weight of the vehicle during service To lift the rear place the floor jack under the rear axle housing and lift vehicle until jack stands can be placed under the rear unibody at the right and left sides to allow working on the vehicle Lower vehicle onto stands and remove floor jack When work is completed reuse floor jack lift and then remove jack stands and lower vehicle to the floor To lift the front place the floor jack under axle beam and lift Place jack stands under the frame at the right and left sides to allow working on the vehicle Lower vehicle onto stands and remove floor jack When work is completed reuse floor jack lift and then remove jack stands and lower vehicle to the floor Hydraulic floor lift Frame lift Position vehicle over lift Place lift arms under the frame of the vehicle and lift to service the vehicle Jack stands
31. vehicle by the owner or operator Weekly maintenance should be performed on a weekly basis to include all daily maintenance and should be performed by the owner operator or trained maintenance personnel Service amp Maintenance Schedule Clean terminals and wash battery Page 3 10 case Check electrolyte level Page 3 10 Batteries Page 3 8 Spot check battery specific gravity Inspect batteries for corrosion loose connections amp broken or Page 3 10 frayed cables Tie Rods Linkage Check for 1 est Drive excessive movement tightness of hardware 3 4 Service amp Maintenance Schedule For proper tire inflation refer to manufacture s recommendation imprinted on tire sidewall Initial factory tire pressure is 35 50 psi Page 3 17 for 5 70 x 8 Setting NOT to exceed tire sidewall rated capacity of 75 psi at full load Electrical wires Check for tightness or damage omar Grounding wires Check for WEJ or damage Visual Electrical inspect motor brushes 8 brush System springs replace if necessary Page 3 7 Check the general condition of the electrical system loose Vi isual connections frayed or broken cables shorts etc Check brake fluid level hydrulic brakes Visual Check brake pads Replace if Fa necessary 3 14 3 12 3 13 Inspect for loose hardware bolts amp nuts etc Body and Clean Body and Seats wash as Ls prame needed ioi ecc IE undercarr
32. 0 00 4 898539 Rin Smp O O 5 NA Armature amp Fan Assy NA Nu amp WaherPacage 1_ oo ZA Frame amp Field Coil Assy o y OS 82 0 Screw Pole 8 9 83301 00 Brosh a 83283 89A Kit Lead Assembly 10 11839 Spring Brush a 3284 89A Brush Plate amp 1 13 Washer Wavy 1 14 Commutator Endhead 1 90 89 Plug 1 Z zia zi o a gt gt oo ZI N Headband Assy 4 7 Drive System em Pat Description Q amp 2 933095 Dum Bake O N 82885 00 Axle Complete W Weldments Not Pictured in Illustration Drive System cont 2 33415 00 Backing Plate Chain Housing 1 Screw Cap 3 8 16 x 2 Backing Plate to Differential Sprocket 67 Tooth Sprocket 86 Tooth Screw Cap 3 8 16 x 1 Sprocket to Flange Washer Lock Sprocket to Flange 33441 00 Chain 45 Link Chain 52 Link Adjuster Chain Tension Screw Cap 3 8 16 x 1 1 4 Washer Lock 3 8 Screw Cap 3 8 16 x 1 Washer Flat 3 8 Housing Chain Screw Cap 1 4 20 x 3 1 4 Washer Flat 1 4 Locknut 1 4 x 20 41204 63A Key Sprocket to Motor Sprocket 17 Tooth Sprocket 19 Tooth Screw Set Sprocket to Motor 69401 00 Motor See Motor Page 4 7 for Detail 33402 00 Differential See page 4 10 for Detail Not Pictured in Illustration Le
33. 6 Spring to Frame 3416 Screw Hex Cap 3 8 16x3 1 2 Spring to Frame Not pictured in Illustration WTO Nn re Dio 864 00 6863 00 tA o6 Ww w 2 I tA 2 o o gt 600 00 Sn natn AININ oo eio O bo Item 6 8 9 ai Rear Suspension Rear Suspension Description Spring Assy 4 Leaf BC3 21 BC4 18 BC3 30 BC4 25 amp XB Models Spring Assy 7 Leaf BC3 40 BC4 35 amp XB Models 54836 00 Spring Assy 8 Leaf BC3 50 amp BC4 45 XB Models 5204 U Bolt Rear Axle 5214 U Bolt Rear Axle 6 amp 7 Leaf sizes 5283 U Bolt Rear Axle 8 Leaf sizes 54815 00 Plate Spring to Rear Axle 5880 Nut Bolt to Spring Lockwasher U Bolt to Spring Shackle Spring to Frame Bushing Spring to Frame Spacer Spring to Frame Screw Hex Cap 3 8 16 x 3 3 4 Spring to Frame 0 Locknut 3 8 16 Spring to Frame Screw Hex Cap 3 8 16x3 1 2 Spring to Frame 2 4 5 Motor Traction Direct Drive Motor Advanced DC Direct Drive Description 69201 00 Motor Complete Armature Assy Kit Field Coil Spring Brush 83284 89 Brush Plate amp Box Assy Ring Snap 8 83286 89A Bearing 9 83288 89A Commutator Endhead Set Brush Cover Plate Assy Plug End Cap 83291 89A Bolt End Cap 4 6 Motor Traction Chain Drive 94
34. Front For Front Wheel Brake Option Only 4719 W Screw Hex Cap 3 8 16x3 4 7038 B Lock washer 3 8 Note See Pages 4 18 and 4 19 for Caliper Assembly exploded views Hydraulic Drum Brakes Light Duty Hydraulic Drum Brakes Part amp Description ssembly Brake LH Compl Incl Items 3 18 ssembly Brake RH Compl Incl Items 3 18 djusting Screw ut Pivot Adj Screw ocket Adj Screw pider Torque 1886 93 Boot amp Ring Wheel Cylinder crew Bleeder 41890 93 up Hydraulic 41892 93 iston Wheel Cylinder 41894 93 trut amp Lever Assembly Parking Brake et Shoe amp Lining Assembly pring Shoe Return LH Green 41916 93 Spring Shoe Return RH Red 41918 93 pring Adj Screw lt ie Pin Retainer Parking Brake Lever Shield Dust 8 Spring Shoe Hold Down When Repairing Items 1 2 6 OR 17 Rear Axle Disassembly and Repair Parts Will be Required a a a S 4 12 13 Parking Brake Linkage Brake Linkage em Description 41342 00 od Pull 73065 00 levis 7 la ut UNC 2B 5 16 18 in Clevis_5 16 x 1 in Hitch 13 ables Brake Rear 7 levis ut Hex Hd 5 16 24 lip Brake Cable rake Hand Assembly racket Handbrake Mount crew Black 5 16 18 x3 4 Bracket to Kick Panel rew Hex Cap 5 16 18 x 1 1 2 able Handbrake to Rear Cable ar Parking Brake Extension 17 1 2 XB Models Bar Parking Brake Extens
35. Illustration 1222 0 1222 0 959 1267 00 1275 00 1207 00 1259 00 1203 00 1221 00 1223 00 1212 00 1225 00 1224 00 1216 00 1226 00 686 1206 00 1220 00 1269 00 1333 00 1219 00 1268 00 1842 94 1230 00 5059 96 744 ALO ARI ojo CD i c lt 1229 00 2407 00 1350 00 Po pd s se en es cd Fed ea 828 W L y 1 op gt Item ES 6 Er A 15 4 16 4 4 14 ped dX I peg WMI LI ojroedg 80 7 Sexe1q 3401 UJIM posn 1511915 YIM SUIOJ xII 4 15 Brakes Rear Caliper Assembly Calipers Rear Brake m Description ssembly Caliper L Rear ssembly Caliper R Rear oot Dust iston Ring ojojo 2 i leeder aliper Carrier Lower rake Pads aliper Carrier Upper onnector Male Brass arking Brake Actuating Pin 12 ever VIO r k lt Use this orientation for 6 Left handed units Use this orientation for gt Right handed units 12 Use this orientation for Right handed units For left handed units install on opposite side 4 16 Brakes Front Caliper Assembly Calipers Front Brake Description Assembly Caliper L Front Assembly Caliper R Front 41361 00 Boot Dust 41359 00 Piston O Ring Bleeder aliper Carrier Lower 7 41297 00 Brake Pads Caliper Carrier Upper 41224 00 Connector Male Brass Note B
36. Shooting Guide XP Plus Speed Control System Note Always follow trouble shooting guide in exact order as listed below Performing tests out of sequence will cause inaccurate results and lost time in diagnosing electrical system problems Note If vehicle equipped with Keyswitch and Forward amp Reverse switch turn key on then place switch in desired position forward or reverse Vehicle Does Not Operate Forward or Reverse Voltmeter positive red lead to battery terminal Voltmeter negative black lead to battery B terminal Key switch in forward Voltmeter positive red lead to red wire at forward solenoid small terminal Voltmeter negative black lead to battery negative B terminal Key switch in reverse Voltmeter positive red lead to yellow wire at reverse solenoid small terminal Voltmeter negative black lead to battery negative B terminal Key switch in forward depress accelerator pedal Voltmeter positive red lead to red wire at forward solenoid small terminal Voltmeter negative black lead to gray wire at forward solenoid small terminal Key switch in forward depress accelerator pedal Voltmeter positive red lead to yellow wire at reverse solenoid small terminal Voltmeter negative black lead to gray wire at reverse solenoid small terminal Key switch in forward depress accelerator pedal Voltmeter positive red lead to white wire at main solenoid Voltmeter negative black lead to gray wire at main solenoid Key
37. accelerator pedal Voltmeter positive red lead to controller terminal Voltmeter negative black lead to controller M terminal Key switch in forward depress accelerator pedal Voltmeter positive red lead to controller terminal Voltmeter negative black lead to 1 terminal at forward solenoid Key switch in forward depress accelerator pedal Voltmeter positive red lead to controller terminal Voltmeter negative black lead to 2 terminal at forward solenoid Key switch in forward depress accelerator pedal Voltmeter positive red lead to controller terminal Voltmeter negative black lead to traction motor S 2 terminal Key switch in forward depress accelerator pedal Voltmeter positive red lead to controller terminal Volt meter negative black lead to traction motor S 1 terminal Key switch in forward depress accelerator pedal Voltmeter positive red lead to controller terminal Voltmeter negative black lead to 3 terminal of reverse solenoid Key switch in forward depress accelerator pedal Voltmeter positive red lead to controller terminal Voltmeter negative black lead to 4 terminal of reverse solenoid Key switch in forward depress accelerator pedal Voltmeter positive red lead to controller terminal Voltmeter negative black lead to traction motor A 2 terminal 5 5 Full battery voltage 2 Good Full battery voltage 2 Good As accelerator is depressed battery voltage should ris
38. ame Raise the vehicle until the tire clears the ground 4 Place Jack Stand s under unibody for additional safety 5 Remove lug nuts and wheels Wheel amp Tire Replacement 1 Toinstall wheel to hub reverse above procedures and run the lug nuts up to the wheel by hand until all nuts are snug against the wheel and the wheel is up against the brake drums 2 Tighten the lug nuts evenly in a star pattern until the nuts are all seated and torque to 50 60 ft Ibs A CAUTION The lug nuts must be lightly snugged in a star pattern then torqued in a crossing pattern or the wheel may be bent causing it to wobble A CAUTION Replacement tires must be of the same size as original equipment Increased Tire load ratings are permissible but the tire rating does not increase the vehicles rated load carrying capacity of the vehicle Tire Care 1 Improper inflation will shorten the life of your tires and will adversely affect performance For proper tire inflation refer to manufacturer s recommendation imprinted on tire sidewall Initial factory setting is 35 to 50 psi NOT to exceed tire sidewall rated capacity of 75 psi at full load 3 18 LUBRICATION Differential The lubricant level in the differential should be checked upon receipt of vehicle then every 6 months If lubricant is needed use SAE 80 gear oil Do not overfill Lubricant should not go above the bottom of the filler plug hole when the vehicle is level 72 Oz in the automotive ax
39. an example being the frame or axle housing After the vehicle is lifted to a 10 to 25 angle place jack stands under vehicle rear unibody to support vehicle weight for added safety Refer to figure 5 Note Be careful and watch for cables linkages or wire harness A CAUTION Jack stands should be of sufficient rated weight capacity to hold the vehicle safely See general vehicle specifications for empty weights A CAUTION If any vehicle is raised while loaded check that the load is secured before lifting vehicle Failure to do so could cause damage to vehicle load or cause personal injury Hoist lifts A CAUTION Before lifting ALWAYS block wheels and set parking brake If a hoist lift is used to lift the vehicle check that the hoist is rated at a lifting capacity greater than the vehicle weight Lift the vehicle sufficiently from the floor to a 10 to 25 angle to allow the placement of jack stands and to support the weight of the vehicle during service To lift the rear connect the lifting eyes hooks to the rear frame at the right and left sides DO NOT use the bumper as a lifting point Place jack stands under the unibody at the right and left sides to allow for working on the vehicle Then lower vehicle to proceed working on the vehicle When work is completed again lift and then remove jack stands and lower vehicle to the floor To lift the front connect the lifting eyes hooks to the front undercarriage by leaf springs DO NOT
40. arehouses factories industrial sites motels parks and resorts Before you drive this vehicle please observe the following safety rules and guidelines Do not drive this vehicle unless you are a qualified and trained operator Keep all body parts head arms and legs inside this vehicle while it is moving This vehicle may overturn if turned sharply when driven at high speeds especially when on an incline Keep the vehicle under control at all times horseplay or dangerous driving Do not drive this vehicb in hazardous areas unless this vehicle is approved and labeled for such operation Immediately report any accident or vehicle problem to your supervisor Driver Training Program The owner of this vehicle shall conduct an Operator Training program for all those who will be operating this vehicle The training program shall be in accordance with O S H A s 29 CFR 1910 178 Powered Industrial Truck Training PITOT standard Successful completion of the Operator training program shall be required for all personnel who operate this vehicle The Operator Training program shall include the following Operation of this vehicle under circumstances normally associated with your particular environment Emphasis on the safety of cargo and personnel safety rules contained within this manual Proper operation of all vehicle controls vehicle operation and driving test Re evaluation on the abov
41. arts to come in contact with oil or grease Just a trace of grease or oil in the hydraulic system may cause damage to rubber parts 3 16 HYDRAULIC SYSTEM Brake Fluid Maintenance cont 1 Maintain fluid level within 1 4 of master cylinder filler opening 2 Changing Brake Fluid a b As a result of use brake fluid loses some of its original qualities and may become contaminated When performing major brake work to the hydraulic system remove old fluid and replace it with clean brake fluid Brake fluid must be changed following extended usage or contamination Anytime fluid looks milky or dark there are contaminants in the fluid If any of the hydraulic system parts are corroded or the fluid is discolored flush the hydraulic system to re move old fluid then fill with clean brake fluid 3 Contamination Soft or swollen rubber parts or milky or discolored fluid indicate the brake fluid is contaminated a Drain old fluid from the system b Replace cups and seals c Flush hydraulic system with clean brake fluid d Refill system with clean brake fluid 4 Handling and Storing Brake Fluid a Keep the brake fluid clean Do not allow any foreign material in the fluid b Prevent any petroleum product gasoline kerosene oil grease etc from contaminating the brake fluid c Useonly clean containers for dispensing brake fluid Do not use containers contaminated with dirt oil grease rust etc
42. atteries are extremely explosive and battery electrolyte is a strong acid See Proper Care and Maintenance of Electric Vehicle Industrial Batteries described in this section A WARNING Batteries contain sulfuric acid which is highly corrosive and can cause chemical burns Avoid contact with skin eyes or clothing Always wear approved eye protection when working around batteries Antidote Extemal Flush with water Internal Drink large quantities of milk or water followed by Milk of Magnesia vegetable oil or beaten eggs CALL DOCTOR IMMEDIATELY Eyes Flush with water get immediate medical attention Battery Testing Specific Gravity Test It is possible to estimate a battery s ability to perform by measuring the specific gravity of each cell with a hydrometer The hydrometer readings indicate two things a State of Charge the amount of electrical power stored in the battery b Condition The ability of battery to store and deliver power Note Always fully charge batteries before performing specific gravity tests to determine battery condition State of Charge Specific Gravity 80 100 1 250 1 270 75 1 220 1 240 50 25 Specific Gravity Taken from at Least 2 Cells of Each Battery Using the Hydrometer 1 Squeeze rubber bulb and insert nozzle into cell release bulb slowly drawing electrolyte up into barrel 2 Adjust electrolyte level in barrel so float rises free of bottom but is not strikin
43. celerator micro switch defective or charger interlock Less than full battery voltage low batteries poor or corroded connections No voltage defective resistor If full battery voltage replace welded main solenoid No increase or voltage drops replace defective main solenoid Less than full battery voltage check for loose or poor connections from main solenoid 1 terminal to controller B and to motor 1 Vehicle Does Not Operate Forward or Reverse Key switch in forward depress accelerator pedal Voltmeter positive red lead to controller terminal Voltmeter negative black lead to controller M terminal Key switch in forward depress accelerator pedal Voltmeter positive red lead to controller terminal Voltmeter negative black lead to large side terminal at reverse solenoid Key switch in forward depress accelerator pedal Voltmeter positive red lead to controller terminal Voltmeter negative black lead to S2 terminal attraction motor Key switch in forward depress accelerator pedal Voltmeter positive red lead to controller B terminal Voltmeter negative black lead to traction motor S 1 terminal Key switch in forward depress accelerator pedal Voltmeter positive red lead to controller B terminal Voltmeter negative black lead to bottom terminal of forward solenoid Key switch in forward depress accelerator pedal Voltmeter positive red lead to controller terminal Voltmeter negative
44. cket Replacement Brake System 3 14 Handbrake Parkbrake Arm Disc Brakes 3 15 Adjustment Replacement Rotor Replacement Front 3 15 Rotor Replacement Rear 3 16 Rotor Wear Limits 3 16 3 a MAINTENANCE AND SERVICE cont Hydraulic System Brake Fluid Maintenance Bleeding Hydraulic System Wheel amp Tire Service Removal amp Replacement Care Lubrication Differential Wheel Bearing Steering Gear Chain Cover Pivot Points With Grease Fittings Without Grease Fittings Body amp Cab Body Upholstery Cab Windows 3 b 3 18 3 19 3 19 MAINTENANCE GUIDELINES To ensure that the Burden Carrier is kept in a safe and correct operating condition the vehicle must be inspected and maintained on a regular basis Proper lubrication electrical control adjustments safety feature inspections etc must be performed at recommended intervals to prevent damage or failure while providing optimum performance A WARNING No modifications or additions which affect the mechanical or electrical integrity and the safe operation of the unit shall be made without the written approval of the manufacturer If such modifications are approved the capacity operation and maintenance instruction markings shall be changed accordingly In no case shall the safety factors be reduced below those specified in this manual or the manufacturers design factors whichever is greater This section explains how to perform maintenance procedures
45. d Install micro switch plate to spacers on switch assembly cover Refer to Pot Switch Adjustment for final internal adjustment recommendations before use WARNING Any time that a pot switch is disassembled it must be adjusted before put into use Failure to perform this adjustment could cause accident or injury Pot Switch Adjustment To adjust pot switch 1 2 Loosen screw clamping speed switch lever to pot switch With volt ohm meter connect black and white lead wires wires must be disconnected from speed control module for this test With speed switch lever released rotate pot switch using a straight screwdriver until correct reading of 0 to 50 ohms is observer Torque speed switch lever clamp screw and rotate speed switch lever to full speed position Check for 4500 to 5500 ohms Adjust pot switch as required only if necessary to achieve correct ohm resistance value CAUTION If resistance results are inconsistent or erratic the pot switch must be replaced Installation 1 nS Set speed switch into place on frame mount and install speed switch mount screws Do not torque screws at this time Connect accelerator linkage using clevis pin washer and new cotter pin CAUTION As linkage is connected check that accelerator rod moves freely without interference with frame or other components Tension from interference will damage switch over time and cause pot switch failure Adjust accelerated
46. e criteria and retraining at least once every three 3 years Safety Instructions cont Driver Qualifications Only those who have successfully completed the Operator training program are authorized to drive this vehicle Operators must possess the visual auditory physical and mental ability to safely operate this vehicle as specified In the American National Standards Institute Controlled Personnel and Burden Carriers ANSI B56 8 The following are minimum requirements necessary to qualify as an operator of this vehicle Demonstrate a working knowledge of each control Understand all safety rules and guidelines as presented in this manual Know how to properly load and unload cargo Know how to properly park this vehicle Recognize an improperly maintained vehicle Demonstrate ability to handle this vehicle in all conditions Safety Committee If the Industrial Vehicles are to be operated by renters or company employees we recommend that a safety committee be appointed The primary concern of this committee should be the safe operation of the vehicles Subjects which must be considered include but are not limited to the following Define where the vehicles should be driven and utilized Ensure all proper warnings as to driving hazards are properly displayed and visible Safety signage concerning hills ramps turns blind crossings intersections etc is highly recommended Define who should and who should not driv
47. e the vehicles Enforcement of safe driving and operating rules Provide driver training for first time operators and review safe operating recommendations regularly Maintain vehicles in a safe operating condition maintain a schedule for daily weekly monthly quarterly semi annually and annual vehicle inspections Who when and how should pre operation inspections be conducted What to do should an unsafe condition or operating problem be discovered These basic rules of operation combined with courtesy and common sense will help make driving your Columbia Industrial vehicle a safe and pleasant experience The safety committee should be made up of managers and or supervisors in charge or responsible for the operation and maintenance of the vehicles 2 3 Vehicle Operating Controls Operator Label VIN Label STOP VEVACLE BEF TNT 7mm Figure 1 Operating Controls 2 4 Vehicle Operating Controls con 1 Parking Brake All Burden Carrier models are equipped with a parking brake lever located on the kickpanel between the driver and the passenger seats To operate pull up and back to engage push forward and down to disengage A CAUTION Parking brake must be engaged whenever vehicle is left unattended 2 Key Switch The key switch is located dash panel When the key switch is in the vertical position the vehicle s speed control system is turned OFF Turn key to the right from vertical to move the veh
48. e to within 1 to 2 volts of battery voltage Full battery voltage 2 Good Full battery voltage 2 Good Full battery voltage 2 Good Full battery voltage 2 Good Full battery voltage 2 Good Full battery voltage 2 Good Full battery voltage 2 Good No increase or voltage drops replace defective main solenoid Less than full battery voltage check for loose or poor connections from main solenoid 1 terminal to controller B and to motor 1 Refer to speed switch testing below before continuing If speed switch testing concludes speed switch is good then controller has failed If low or no voltage check cables and cable connections from controller M to forward solenoid 1 terminal If low or no voltage replace defective forward solenoid If low or no voltage check cables and cable connections from forward solenoid 2 terminal to forward 3 and to motor S 2 Defective field coil in traction motor See Traction Motor page 3 7 for repair procedures If low or no voltage check cables and cable connections from motor S 2 terminal to reverse solenoid 3 terminal Less than full battery voltage replace defective reverse solenoid If low or no voltage check cables and cable connections from reverse solenoid 4 terminal to forward 3 and to motor 2 Vehicle Does Not Operate Forward or Reverse Key switch in forward depress accelerator pedal Voltmeter positive red lead to A 1 term
49. ed and they most certainly can be prevented operators must accept their full measure of responsibility While the designer the manufacturer and the safety engineer can help minimize the possibility of an accident their combined efforts can be erased by a single careless act It is said The best kind of safety device 15 a careful operator We ask you to be that kind of person A CAUTION To prevent possible injury always disconnect batteries before working on the vehicle Remove both the positive and the negative battery cables as shown in Figures 1 and 2 DISCONNECT METHODS Operational Installation Standard TO 30 AMP FUSE TO MOTOR S1 DISCONNECT Figure 1 Standard Installation 1 2 Optional Installation Push Pull Battery Pack DISCONNECT TO FWD REV TO 30 AMP FUSE TO MOTOR 51 Note the Battery Polarity with this configuration Figure 2 Push Pull Batteries Installation CAUTION No modifications or additions which affect the mechanical or electrical integrity and the safe operation of the unit shall be made without the written approval of the manufacturer If in doubt about any modification contact your local Columbia Industrial amp Commercial Vehicle Dealer or Columbia ParCar Corp Customer Service N WARNING rec Ot ATP COP rm vereis Figure 3 Push Pull Batteries Installed 1 3 ALL VEHICLES gt Any modifications or changes to the vehicle tha
50. em Lifting Instructions CHAPTER 2 OPERATOR INFORMATION Safety Instructions Rules amp Guidelines Driver Training Program Driver Qualifications Safety Committee Vehicle Operating Controls Vehicle Operation Instructions Pre Operations Checklist Operational Safeguards Driving the Vehicle Vehicle Storage Storage Preparing for Storage Returning to Service CHAPTER MAINTENANCE SERVICE Maintenance Guidelines Checklist Troubleshooting Hints General Safety Precautions Maintenance Procedures Electrical System Motor Brushes Motor Removal Batteries Testing Inspection amp Maintenance Removal nstallation Battery Charger Operating Instructions Charging Batteries Outside Vehicle Bulbs Fuse and Flasher Replacement Chart Drive System Drive Chain Adjustment Chain and or Sprocket Replacement Brake Systems Handbrake Cable Inspection Park brake Arm adjustment Disc Brakes Adjustment Replacement ok oo cn 2 2 2 3 2 7 2 8 3 3 3 3 3 6 3 6 3 7 3 7 3 7 3 12 3 12 3 13 3 13 3 14 Table of Contents cont Rotor Replacement Front Replacement Rear Wear Limits Hydraulic System Brake Fluid Maintenance Bleeding Hydraulic System Wheel and Tire Service Wheel and Tire Removal Wheel and Tire Replacement Tire Care Lubrication Differential Wheel Bearings Steering Gear Chain Cover
51. erator speed switch position Up At rest Solenoid F eee Not energized connection between bottom terminals top terminals open Solenoid Not energized connection between bottom terminals top terminals open Solenoid M eee Not energized large terminals open Controller 1 tab terminal Not energized Forward Operation Key switch position forward Accelerator pedal depressed Solenoid E Energized connection between large top terminals large bottom terminals open SOLENOID Rote Not energized contact between large bottom terminals large terminals open Solenoid M Energized contact between large top terminals Controller 1 tab terminal Energized Reverse Operation Key switch position reverse Accelerator pedal depressed Solenoid F ees ee Not energized contact between large bottom terminals large top terminals open Solenoid tees Energized connection between large top terminals large bottom terminals open Solenoid M itt Energized contact between large terminals Controller 1 tab terminal Energized Trouble Shooting Guide M 18 Speed Control System Note Always follow trouble shooting guide in exact order as listed below Performing tests out of sequence will cause inaccurate results and lost time in diagnosing electrical system problems Note If vehicle equipped with Key
52. everse solenoid from motor S 2 terminal to reverse solenoid 3 terminal Key switch in forward depress accelerator pedal Voltmeter Full battery Less than full battery voltage positive red lead to controller B terminal Voltmeter voltage Good replace defective reverse negative black lead to 4 terminal of reverse solenoid solenoid Note Always follow trouble shooting guide in exact order as listed below Performing tests out of sequence will cause inaccurate results and lost time in diagnosing electrical system problems Voltmeter positive red lead to battery B terminal Voltmeter Full battery Less than full battery voltage negative black lead to battery B terminal voltage 2 Good charge and or replace batteries 1 Key switch in forward Voltmeter positive red lead Full battery Less than full battery voltage to red wire at forward solenoid small terminal voltage 2 Good check key switch and wire Voltmeter negative black lead to battery negative harness B terminal 2 Key switch in reverse Voltmeter positive red lead to yellow wire at reverse solenoid small terminal Voltmeter negative black lead to battery negative B terminal Key switch in reverse depress accelerator pedal Voltmeter Full battery Less than full battery voltage positive red lead to yellow wire at reverse solenoid small voltage Good accelerator micro switch or terminal Voltmeter negative black lead to gray wire at micro switch circuit defec
53. g top of barrel 3 8 BATTERY TESTING cont 3 Hold hydrometer vertically making sure float moves freely and is not contacting sides of barrel Read electrolyte level in relation to the scale printed on the float 4 Record the reading 5 Return electrolyte to cell from which it was removed 6 Repeatthese steps on all battery cells Note ALWAYS rinse the hydrometer in Fresh clean water after use The temperature of the electrolyte being tested affects hydrometer readings Measure the temperature of the electrolyte and correct your readings as follows Above 80 F Add 004 to the specific gravity readings for each 10 above 80 F Below 80 F Subtract 004 from the specific gravity readings for each 10 below 80 F Interpretation of Hydrometer Readings State of charge Check specific gravity of each cell Refer to tables below State of Charge Specific Gravity 80 F 100 1 250 1 270 1 220 1 240 7190 7210 1 160 1 180 Condition If the difference between the highest and lowest cell is 050 50 points more the battery is nearing the end of its useful life The batteries should be replaced as a set Note If the highest cell reads less than 1 200 the test for condition is questionable Recharge battery and perform test again Inspection and Maintenance New batteries should be given a full charge before their first use because it is difficult to know how long the batteries have been in storage with
54. he brake caliper mounting bracket 4 Remove caliper assembly by sliding off rotor Do not disconnect hydraulic line from caliper 5 The rotor may now be removed from the spindle by removing the dust cover cotter pin and spindle nut 6 Atthis point the rotor may be either resurfaced See Rotor Wear Limits or replaced with a new rotor 7 To replace rotor reverse steps through 5 3 15 ROTOR REPLACEMENT cont 8 Use caution when remounting the brake calipers Tighten each of the 5 16 bolts gradually alternating from one to the other As you tighten the bolts be certain that the pads are parallel to the disk if they are not a spongy brake pedal may result Also be sure that the caliper can still move back and forth in the caliper housing mounting if it can t uneven pad wear will result 9 Reinstall wheel and tire Tighten the lug nuts evenly in a star pattern until the nuts are all seated and torque to 50 60 ft 165 Rotor Replacement Rear Wheel A CAUTION Disconnect batteries and block front wheels and raise rear of vehicle off the ground See chapter 1 for lifting instructions 1 Remove wheel and tire 2 Remove parkbrake cable from park brake arm on the caliper Access Slot 3 Remove the two 5 16 bolts from the brake caliper mounting bracket 4 Remove caliper assembly by sliding off rotor Do not disconnect hydraulic line from caliper 5 Remove the four 3 8 lock nuts from the inside face of the axle
55. housing flange accessible through slots in the brake rotor 6 The axle shaft may now be removed with a slide hammer puller 7 Remove the four 5 16 bolts from the brake rotor mounting flange and remove rotor 8 At this point the rotor may be either resurfaced See Rotor Wear Limits or replaced with a new rotor 9 Complete re assembly by reversing steps through 7 10 Use caution when remounting the brake calipers Tighten each of the 5 16 bolts gradually alternating from one to the other As you tighten the bolts be certain that the pads are parallel to the disk if they are not a spongy brake pedal may result Also be sure that the caliper can still move back and forth on the mounting pins if it can t uneven pad wear will result Reinstall wheel and tire Tighten the lug nuts evenly in a star pattern until the nuts are all seated and torque to 50 60 ft 165 Figure 10 Rear Rotor 11 Rotor Wear Limits The limits for resurfacing of the brake rotor are 1 32 inch per side for a total of 1 16 inch The overall thickness of the rotor should be no less than 3 16 inch HYDRAULIC SYSTEM Check the brake fluid in the master cylinder periodically under normal conditions every 3 months The master cylinder is located under the front deckboard and seat assembly Brake Fluid Maintenance Note Use DOT 3 Motor Vehicle Brake Fluid A CAUTION Do not handle hydraulic system parts with greasy hands or permit p
56. hree times a week Water electrolyte le vels drop as batteries are discharged and rise during charge Adding water when batteries are fully charged will reduce E Pall the probability of overfilling See Figure 2 Figure 2 Electrolyte Maximurr Minimum When the temperature falls below 65 F batteries should be placed on charge as soon after use as possible In these low temperatures an additional equalizing charge once a week will improve the state of charge and battery life Be sure battery hold downs are properly tightened A loose hold down may allow the battery to become damaged from vibration or jarring A hold down that is too tight may buckle or crack the battery case Batteries must be clean and dry Dirt and electrolyte on top of batteries will cause batteries to self discharge Clean battery tops with a baking soda sodium bicarbonate and water solution 5 teaspoons baking soda per quart water Do not allow solution to enter cap vent holes Check to see that battery cap vent holes are clear Plugged vent holes will not permit gas to escape from the cell and could result in battery damage Inspect battery posts clamps and cables for breakage loose connections and corrosion Remove cables to clean battery posts and clamps when signs of corrosion appear Inspect battery case for cracks or leaks Battery Removal 1 Remove battery negative cables 2 Remove battery posi
57. iage In replace if 3 18 LIII 3 18 ES dd 3 18 Pivot points without grease fittings Page3418 Check differential Fluid Always Page check upon receipt of vehicle 3 18 Refer to individual maintenance sections of this manual for details of Service Maintenance Operations Before operating the vehicle inspect vehicle for damage check operating controls including Reverse Warning Alarm check tires for proper inflation and test drive TROUBLESHOOTING HINTS A CAUTION To prevent possible injury always disconnect batteries and remove key before working on vehicle Troubleshooting Hints Chart Problem Possible Remedy Cause Key Switch Check for loose wires or faulty switch Batteries Check for loose terminals or corrosion Check distilled water Vehicle will not run level Check battery state of charge Motor Check for loose wires open circuits or worn brushes Speed Control See troubleshooting guide in appendix F Check for loose terminals or corrosion Check distilled water level Check battery state of charge Vehicle runs slow Check for dragging brakes Check for under inflated or flat tires Check to see that wheels are not binding and spin freely ar these test procedures do not resolve your vehicle problem contact your authorized Columbia Industrial amp Commercial Vehicle Dealer The Service and Maintenance section that follows contains the most current informati
58. icle in forward Turn key to the left from vertical to move the vehicle in reverse Always take the key out of the switch when leaving the vehicle 3 Light Switch The light switch is a two position toggle switch located on the dash panel to the right of the key switch Move switch up to activate headlight and taillights down to turn off 4 Wiper Switch Optional with cabs not shown The wiper switch is a two position toggle switch located on the dash panel located to the right of the light switch Move switch up to operate windshield wiper down to turn off 5 Accelerator Pedal The pedal controls the speed of the vehicle in the same manner as a conventional automobile A CAUTION Speed in reverse should ALWAYS be kept at a minimum 6 Brake Pedal To operate service brakes depress pedal Depressing pedal also activates brakelights 7 Horn Button The horn button is located floor to the left of the steering wheel Press button to sound the horn 8 Steering Wheel The steering wheel controls the path of the vehicle exactly the same as a conventional automobile wheel 9 Turn signal Hazard Warning Switch The turn signal hazard warning switch is located on the steering column below the steering wheel When lever is moved upward right turn signal turns on and upper green light flashes When lever is moved downward left turn signal turns on and lower green light flashes To turn off the a signal move indicator leve
59. imize fire hazards and facilitate detection of loose or defective parts CHECKLIST A good planned maintenance program is important for the safe reliable operation of all Columbia Industrial amp Commercial Vehicles The recommended procedures described in this service manual are effective methods for performing periodic maintenance and repair Note Some procedures require the use of special tools These special tools should be used when and where recommended Note When performing Monthly Quarterly Semi Annual or Annual maintenance insure that Daily and Weekly Inspections are included CHECKLIST cont Note The environment that your vehicle operates in can vary widely Severe conditions or duty cycles will require the periodic maintenance recommendations to be adjusted to more frequent time intervals Examples of severe service operations include but are not limited to the following Dusty or sandy locations such as cement plants lumber or flourmills coal dust or stone crushing areas High Temperature Areas such as steel mills foundries etc 3 Sudden temperature changes such as continuous indoor outdoor movement as in refrigeration plants etc Periodic Service Calendar JANUARY FEBRUARY MARCH Monthly Monthly Quarterly JUNE Semi Annual JULY AUGUST SEPTEMBER Monthly Monthly Monthly OCTOBER NOVEMBER DECEMBER Monthly Monthly Annual Note Daily maintenance is performed daily before operation of the
60. in a cool environment 2 8 Vehicle Storage cont WARNING Turn keyswitch OFF and remove key during storage to prevent Unintentional starting of vehicle gt gt WARNING DONOT attempt to charge a battery that is frozen or if battery case is excessively bulged Properly dispose of battery because frozen batteries can explode If battery terminals or wires are damaged or corroded they should be cleaned or replaced as necessary Failure to do so may cause them to overheat during operation A Caution Batteries in a low state of charge will freeze at higher temperatures than fully charged batteries Preparing vehicle for extended storage Electric vehicles stored over six 6 to eight 8 weeks must be protected to maintain battery life Several guidelines should be observed when storing your electric vehicle 1 Fully charge batteries With electrolyte full in all cells store batteries in a cool place If stored above 50 degrees F 27 C check State of charge every four 4 to six 6 weeks and charge as necessary to maintain 1 250 to 1 270 specific gravity If vehicles are stored in temperatures below 40 F check state of charge every fifteen 15 to eighteen 18 weeks Use figure 4 to determine freezing point of batteries and maximum recommended storage temperature Refer to Appendix C for charging procedure 2 Wash off any corrosion around the terminals with a solution of baking soda and water DO NOT allow this s
61. inal at traction motor Voltmeter negative black lead to A 2 terminal at traction motor Full battery voltage 2 Good If motor does not operate check motor brushes and armature See Traction Motor page 3 7 Speed Switch Pot Box Testing Remove white and black lead wires from controller 2 and 3 1 4 tab terminals Switch volt ohm meter to ohms scale Capable of measuring 0 to 100 ohms Connect volt ohm meter leads to white and black wires from controller Do not depress accelerator Leave key in off position Leave ohmmeter leads connected to white and black leads removed from controller 2 and 3 tab terminals Switch ohmmeter to a scale capable of measuring up to 6 000 ohms K ohms Slowly depress accelerator and monitor change 50 ohms resistance Good Ohms of resistance should rise gradually to a maximum of 4 500 to 5 500 ohms Greater than 50 ohms refer to Pot Switch Adjustment page 5 12 If adjustment does not correct replace pot switch or speed switch assembly See page 5 11 Tf rise in resistance is erratic or skips as pedal is depressed replace pot switch or speed switch assembly f maximum resistance is less than or greater than 4 500 to 5 500 ohms adjust pot switch to correct Refer to page 5 12 Note Always follow trouble shooting guide in exact order as listed below Performing tests out of sequence will cause inaccurate results and lost time in diagnosing electrical
62. ion 3 62 Bed Models Not Pictured in Illustration Q wig KICK PANEL FLOOR FRAME 2 Brake Hydraulic System Hydraulic Disc Brake System Description rake Line 20 Rear Disc Brakes rake Line 20 Front 4 Wheel Disc Brakes XB requires 3 lip Hose Hose to Frame for Front Brakes aliper L Front Brake bow Male Brake Line to Caliper aster Cylinder 4 amp 2 Wheel Drum Brakes 4 Hole Mounting aster Cylinder 4 amp 2 Wheel Disc Brakes 4 Hole Mounting aster Cylinder 2 Wheel Disc amp Drum Brakes 2 Hole Mounting educer Adapter Master Cylinder to Brake Line rake Line 6 witch Stoplight aliper L Rear Brake onnector Brass Brake Line to Caliper Rear ose Brake Hydraulic aliper R Rear Brake ut Nylok 1 4 20 nion Inverted Flair Mid Rear rake Line 60 XB Only rake Line 51 Standard Bed Only Fitting Hydraulic W Brkt To Stoplight Switch rake Line 10 aliper R Front Brake nion Tee 3 16 Hyd Brake od Threaded Master Cylinder oke ut Jam 5 16 24 in Clevis 5 16x1 in Hitch 13 ever Brake Pedal Assembly ad Brake Pedal late Brake Pedal Mounting crew Flat Hd 1 4 20x5 8 Brake Pedal Plate Mounting crew Hex Cap 3 8 16x3 Brake Pedal Assy Mounting ocknut Nylok 3 8 16 Pedal Assy Mounting 1833 pring Brake Return 3 8x5 1232 00 racket Spring Mounting Front Wheel Kit Incl Items 1 2 3 4 6 10 11 17 18 amp 19 Not pictured in
63. irst and third terminals on micro switch 2 With micro switch lever depressed no continuity should be observed 3 With micro switch lever released continuity should be observed 4 If results of your test are erratic or inconsistent with the above the micro switch must be replaced Pot Switch Test 1 Using a digital volt ohm meter set to test continuity probe to the terminals at ends of black and white lead wires 2 With speed switch lever released 0 to 50 ohms will be observed 3 With speed switch lever depressed completely 4500 to 5500 ohms will be observed 4 As speed switch lever is depressed resistance should rise smoothly from 0 to 50 ohms to a maximum of 4500 to 5500 ohms 5 If resistance value observed is incorrect refer to Pot Switch Adjustment page 5 12 CAUTION If resistance readings are erratic and inconsistent the pot switch must be replaced Removal 1 Remove red and black wires from micro switch mounted to speed switch 2 Remove white and black leads from speed control module 2 and 3 tab terminals Remove wire ties securing speed switch lead wires to frame 5 10 4 Remove cotter pin and accelerator clevis from speed switch lever Note which position clevis pin was removed from You will need to reinstall to original position 5 Remove screws securing speed switch to frame Remove speed switch from vehicle Disassembly Note Refer to Figure 2 1 Remove two screws Figure 2 11 holdi
64. jury or death Only trained maintenance professionals should repair or service this vehicle A Persons doing even simple repairs or service should have working knowledge and experience in general electrical and mechanical repair WARNING Follow all procedures exactly and observe all warnings stated in this manual Use caution and common sense Proper service and repair is important for the safe reliable operation of all Columbia Industrial Vehicles The service procedures recommended and described in this service manual are effective methods for performing service operations Some of these service operations require the use of tools specially designed for the purpose These special tools should be used when and as recommended Moving parts hazard When operating any vehicle in a stationary position avoid spinning clutches belts and wheels that could snag clothing or cause severe injury to body parts A running vehicle must be worked on with the greatest care Use caution and common sense Working on Columbia Industrial Vehicles without following proper procedures and using proper lifting equipment may result in vehicle damage or personal injury See lifting instructions in chapter 1 for detailed instructions Failure to maintain vehicle properly could result in decreased vehicle performance reliability or cause severe personal injury ALL VEHICLES gt Any modifications or changes to the vehicle that affect the stability or that result
65. l Voltmeter negative black lead to battery B terminal Key switch in forward Voltmeter positive red lead to red wire at forward solenoid small terminal Voltmeter negative black lead to battery negative B terminal Key switch in reverse Voltmeter positive red lead to yellow wire at reverse solenoid small terminal Voltmeter negative black lead to battery negative B terminal Key switch in forward depress accelerator pedal Voltmeter positive red lead to red wire at forward solenoid small terminal Voltmeter negative black lead to black wire at forward solenoid small terminal Key switch in forward depress accelerator pedal Voltmeter positive red lead to yellow wire at reverse solenoid small terminal Voltmeter negative black lead to black wire at reverse solenoid small terminal Key switch in forward depress accelerator pedal Voltmeter positive red lead to white wire at main solenoid Voltmeter negative black lead to black wire at main solenoid Key switch in forward depress accelerator pedal Voltmeter positive red lead to white wire at 1 tab terminal of speed control module Voltmeter negative black lead to controller B terminal Key switch in forward depress accelerator pedal Voltmeter positive red lead to controller B terminal Voltmeter negative black lead to large side terminal at reverse solenoid Key switch in forward depress accelerator pedal Voltmeter positive red lead to controller terminal V
66. le 44 Oz in M 18 Dana axle Wheel Bearings Clean inspect and lubricate wheel bearings every 6 months Use Texaco Marfax heavy duty 2 or equivalent Replace worn bearings as needed Steering Gear Check yearly add grease as required Molub Alloy 0 or equivalent Note Replace Steering Cover Gasket Chain Cover Check yearly add grease in center along length as required Molub Alloy 0 or equivalent Pivot Points With Grease Fittings There are 6 lubrication points with grease fittings on the front end of the vehicle one on each of the four tie rod ends and one on each side of the front axle kingpin pivot Under normal conditions these points should be greased every 6 months with chassis lube Pivot Points Without Grease Fittings The handbrake mechanism parking brake linkage and brake pedal lever pivot should be lubricated every 3 months Use light machine oil or motoroil BODY AND CAB MAINTENANCE Body Frequent washings with mild soap will preserve the luster and finish of your vehicle For stubborn and imbedded dirt a soft bristle brush may be used Tar asphalt creosote and the like should be removed immediately to prevent staining of paint A WARNING Avoid direct hose spray on electrical components Upholstery Clean gently with mild soap suds and a soft cloth Cab The Columbia Industrial Vehicle cab optional is constructed of reinforced fiberglass or painted steel Use a mild soap or detergent with a spo
67. lead to main solenoid 2 terminal Voltmeter negative black lead to controller B terminal Key switch in forward do not depress accelerator pedal Voltmeter positive red lead to main solenoid 1 terminal Voltmeter negative black lead to controller B terminal Key switch in forward depress accelerator pedal Voltmeter positive red lead to main solenoid 1 terminal Voltmeter negative black lead to controller B terminal Key switch in forward depress accelerator pedal Voltmeter positive red lead to traction motor A 1 terminal Voltmeter negative black lead to controller B terminal 5 15 Full battery voltage Good Full battery voltage Good Full battery voltage Good No Voltage Good Full battery voltage Good Full battery voltage Good Full battery voltage Good to 5 volts less than full battery voltage Good Full battery voltage Good Full battery voltage Good Less than full battery voltage charge and or replace batteries Less than full battery voltage check key switch and wire harness Less than full battery voltage accelerator micro switch or micro switch circuit defective Full battery voltage diodes between forward and reverse solenoid defective Less than full battery voltage diodes between forward and reverse solenoids defective or accelerator micro switch defective Less than full battery voltage diodes between forward and reverse solenoids or ac
68. leeder may be placed in any of 3 locations lt Steering Linkage Steering Linkage Description Axle Beam Weldment Nut Supplied with Steering Box 1 Washer Lock Supplied with Steering Box 1 Pittman Arm 1 Tie Rod 1 56802 00 Tie Rod End RH Includes Boot Lube Fitting Nut amp Cotter Pin 2 56804 00 Tie Rod End LH Includes Boot Lube Fitting Nut amp Cotter Pin Drag Link 4 18 Steering Gear Assembly 5 Column See page 421fordetal ae 3 a 5 6 8 9 10 11 Seal Worm Shaft 12 Gasket Side Cover WA Shaft Pitman 14 Adjuster Lash 15 Shim Kit Adjuster Preload 16 Cover Side qr Bolts Side Cover 18 Nut Preload Adjuster Parts Shown for display only not sold separately Items show for clarification only Not sold separatel Steering Column Assembly Wheel Steering 14 With Cap 6 2551 W_ Bolt Carriage 1 420x1 o O 8 7039 jLockwasher 7 6 S y O 9 3769 Screw 7 1614 x 11 2 Cap AA 1 7742 Locknut 4 200 Steering Gear Box Screw 5 16 UNC x 3 4 Collar Shaft 3 4 x 1 1 4 Locknut 3 8 19 Steering Shaft 2 1 2 Long Support Steering Column 2879 W Screw Hex Cap 3 8 16 x 1 3 Electrical Wiring 36 and 48 Volt Power System Module Speed Controller 48 Volt 275 Amp Module Speed Controller 36Volt 400
69. low or no voltage replace positive red lead to controller B terminal Voltmeter voltage Good defective forward solenoid gative black lead to 1 terminal at reverse solenoid Key switch in reverse depress accelerator pedal Voltmeter Full battery If low or no voltage check positive red lead to controller B terminal Voltmeter voltage Good cables and cable connections negative black lead to traction motor S 1 terminal from reverse solenoid 1 terminal to reverse 3 and to motor S 1 Key switch in reverse depress accelerator pedal Voltmeter Full battery If low or no voltage check positive red lead to controller B terminal Voltmeter voltage 2 Good cables and cable connections negative black lead to 4 terminal of forward solenoid from motor S 2 terminal to forward solenoid 4 terminal Key switch in reverse depress accelerator pedal Voltmeter Full battery Less than full battery voltage positive red lead to controller B terminal Voltmeter voltage 2 Good replace defective forward negative black lead to 3 terminal of forward solenoid solenoid 5 8 MOTOR amp CONTROL DIAGNOSTICS DIAGRAM Key Switch Connection Off e Electrical Shift FWD N REV Switch Connection Blue Main Solenoid Forward e e le e e e e Red Fwd Solenoid Rev Solenoid Orange Alarm LLL il B D HO D Positioned as Installed flat part of koy up
70. n tension 5 Replace the chain cover using a silicon sealant between the cover and backing plate GE RTV 012 equivalent Replace approximately 3 to 5 lbs of grease with 86T sprocket Molufa Alloy 0 or equivalent 9 Thorough ly clean on Chain Deflection 3 16 Max the backing plate around the 1 8 Min motor Re apply a bead of silicone sealant to the joint between the motor and the backing plate Be sure to fill any newly exposed portions of the slotted motor mounting holes Adjuster Cam Backing Plate Motor Mounting Bolts 4 Req d Figure 4 Chain Tension 3 12 DRIVE SYSTEM cont Chain and or Sprocket Replacement 1 2 3 4 5 6 7 Remove chain cover Loosen the 4 motor mounting bolts Rotate the adjuster cam allowing the motor to move downward relieving tension on chain The chain may now be removed by lifting it off of the sprockets The lower sprocket may be replaced by removing the four sprocket mounting bolts The upper sprocket may be replaced by loosening the two setscrews in the sprocket hub and removing the sprocket from the motor shaft with a gear puller After the required parts have been replaced follow steps 3 through 6 under Drive Chain Adjustment Backing Plate Figure 5 Motor and Backing Plate DRIVE SYSTEM M 18 Drive Belt Adjustment 1 Remove belt cover 2 Loosen the 4 motor mounting bolts slightly see Figure 6 3 Rotate adjuster cam co
71. ng RH Lockwasher 4 046 Weather strip Door Opening Order by Foot a ES EN 6 8 NE MEC LATA N Oo o o NA WwW BY Ww o eio o2 N 17 4 28 Cab Items Item Part Description Wiper Motor 2 12V Option Striker Plate Cab Door Kit Burden Carrier Dome Light Screw Machine 10 24 x 1 4 Plate Mounting Screw Striker Plate Mounting 7998 Nut Striker Plate Mounting 19 48865 ZZ Pinch Weld Around Headlights by Foot 11 4 29 Hitches Item Description 7318 00 Kit Pintle Hitch 5 57307 00 Reinforcing Bracket 2879 W Screw Hex Cap 3 8 16 x 1 6000 B Washer W Plain Type A 3 8 Locknut Nylok 3 8 16 Hitch Mounting Bracket 6 8 EI Screw Hex Cap 3 8 16 x 1 1 4 Bolt Hex Hd Grade 8 1 2 13x1 Locknut Nylok Thin 1 2 13 Hitch Automatic Type To 26 000 Ibs 0 Hitch Pintle Type Harval T60AL Aerol 82003 11 Hitch Automatic Type To 10 000 Ibs 4 30 Options cont Battery Push Pull Kit Description Part it Push Pull Battery Box ox Push Pull ssembly Door 1 Each Side oor Push Pull Door Mounting Hardware inge Push Pull Door Mounting Hardware ivet Body to Door Mounting Hardware olt Body to Door Mounting Hardware asher Body to Door Mounting Hardware ut Body to Door Mounting Hardware tch Door olt Latch to Body Mounting Hardware olt Chain to Latch
72. ng micro switch plate to support spacers 2 Loosen lock screw clamping speed switch lever to pot switch Remove speed switch lever and return spring 3 Remove four screws and remove potbox cover Figure 2 Speed Switch 4 Remove micro switch plate support spacers from cover 5 Remove nut holding pot switch into cover and remove pot switch See Figure 2 2 CAUTION If pot switch is to be removed solder connections must be cut or solder must be melted with soldering iron for wire removal Care must be taken to prevent internal pot switch damage caused by excessive heat when de soldering and soldering 6 Lead wires and grommet can now be removed from box White Assembly 1 Insert lead wires into box with grommet Check that wire length in box is sufficient for connecting pot switch 2 Connect black wire to center tab and white wire to left tabs of pot switch Solder pot witch wires to pot switch tabs See Figure 3 Figure 3 Pot Switch Wires CAUTION Care must be taken to prevent internal pot switch damage caused by excessive heat when soldering Install lock washer onto pot switch insert pot switch into box cover aligning tab on pot switch to engage into hole in cover Install nut to outside of box Install spacers 2 to outside of pot box cover Install cover with pot switch to box Install return spring and speed switch lever to pot switch See Figure 2 Do not torque clamp screw until adjustment has been complete
73. nge or soft cloth for normal cleaning BODY AND CAB MAINTENANCE A WARNING Do not use harsh detergents abrasives or cleaning solvents that contain ammonia aromatic solvents or alkaline material to clean cab Windows Normal window cleaners may be used on glassed areas of cab CHAPTER 4 PARTS LIST Body Items Front Axle amp Suspension Rear Suspension Motor Traction 69201 00 Direct Drive Motor Traction 69401 00 Chain Drive Drive System Differential amp Brakes Direct Drive Drive System Sprockets Motor Chain Assy Chain Drive Drive System Differential Assy Front Rotor Hub Wheels amp Tires Brakes Hydraulic Drum Brake Linkage Parking Brakes Hydraulic System Caliper Assy Rear Caliper Assy Front Steering Linkage Steering Gear Assembly Steering Box Steering Column XP Electrical System M 18 Electrical System M 18 Drive System Accelerator Linkage Options Cargo Retainer Cab Items Hitches Battery Push Pull Kit PAGE 4 2 4 4 4 5 4 6 4 7 4 8 4 9 4 10 4 11 4 12 4 13 4 14 4 16 4 17 4 18 4 19 4 20 4 21 4 23 4 25 4 26 4 27 4 28 4 30 4 31 BODY ITEMS Note The Burden Carriers come in two bed lengths Standard 62 inches length and the Extended Bed XB 76 inches in length For ease in recognition they will be designated in some parts list tables as STD and XB Body Items Body Items It Part D ipti Qty Used NE c 19311 00 Bod
74. nstallation BRAKE SYSTEM Handbrake Parkbrake Arm Adjustment As the brake pads wear thinner one MUST adjust the park brake See Figure 8 to preserve proper hand brake operation Be very cautious when performing this adjustment or doing any work on your brakes Handbrake Parkbrake adjustment is made to hold the vehicle load capacity and driver on 15 grade for 15 minutes ASME B56 8 Parkbrake Adjustment Knob 1 Loosen the lock screw on the hand parkbrake knob 2 Rotate the knob clockwise to loosen brake or counter clockwise to tighten braking Lock Screw Figure 8 Hand Parkbrake BRAKE SYSTEM cont Disc Brakes Most common complaint is noise when brakes are applied and vehicle is rolling slowly Brake pads may require replacement Brake disc may require resurfacing Adjustment Disc Brakes The disc brakes require no adjustment as they are self aligning and self adjusting Pads should be checked for wear periodically and at least every six 6 months Replace as necessary Disc Brake Pad Replacement See Chapter 4 Page 4 16 and 4 17 for exploded views A CAUTION Disconnect batteries and raise the end of the vehicle to be worked on off the ground and block the wheels on the opposite end of the vehicle 1 Remove wheel and tire 2 Remove parkbrake cable from park brake arm on the caliper 3 Remove the two 5 16 bolts from the brake caliper mounting bracket 4 Remove caliper assembly b
75. o perform many of the maintenance items listed as well as many of the service and general repair jobs detailed in the following pages it will be necessary to remove either one or both of the deckboards Handlifts have been incorporated into the deckboards to ease the removal operation To prevent possible injury care should be exercised while removing deck board s 3 6 Maintenance Procedures ELECTRICAL SYSTEMS MOTOR BRUSHES See chapter 4 for exploded view and parts list Check the motor brushes every 3 months for wear and spring tension Visually inspect brushes for cracks chips or wear to a length of 3 4 or less Whenever brushes are replaced replace the entire set Cheek each brush for free movement in its holder Replace any weak brush springs Extensive motor repair work if needed should be handled through your local Columbia Industrial amp Commercial Vehicle dealer or Columbia ParCar Corp Technical Services CAUTION The motor is heavy Use correct lifting procedures to avoid back injury Figure 1 Motor MOTOR REMOVAL 1 Disconnect all wires from the motor Label the leads for easy identification when replacing the motor 2 Remove chain cover 3 Support the motor using a sling or strap 4 Loosen the motor mounting bolts inside chain cover 5 Rotate CCW adjuster cam allowing the motor to move downward relieving tension on chain 6 The chain may now be removed by lifting it off of the sprockets
76. oltmeter gative black lead to S2 terminal at traction motor Key switch in forward depress accelerator pedal Voltmeter positive red lead to controller terminal Voltmeter negative black lead to small bottom terminal of forward solenoid Key switch in forward depress accelerator pedal Voltmeter positive red lead to controller terminal Voltmeter negative black lead to small top terminal of forward solenoid 5 17 Full battery voltage 2 Good Full battery voltage 2 Good Full battery voltage 2 Good No Voltage Good Full battery voltage 2 Good Full battery voltage 2 Good Full battery voltage 2 Good Full battery voltage 2 Good Full battery voltage 2 Good Full battery voltage 2 Good Less than full battery voltage charge and or replace batteries Less than full battery voltage check key switch and wire harness Less than full battery voltage accelerator micro switch or micro switch circuit defective Full battery voltage diodes between forward and reverse solenoid defective Less than full battery voltage diodes between forward and reverse solenoids defective or accelerator micro switch defective Less than full battery voltage diodes between forward and reverse solenoids or accelerator micro switch defective If low or no voltage check cables and cable connections from controller M to reverse solenoid large side terminal If low or no voltage replace defective re
77. olution to enter batteries Store vehicle in a cool dry place to prevent battery discharge 4 For proper tire inflation refer to manufacture s recommendation imprinted on tire sidewall Factory tire pressure set at 35 to 50 psi for 5 70 x 8 tires Grease suspension and continue quarterly lubrication during storage period Clean vehicle body seats battery compartment and vehicle underside 7 DO NOT engage park brake Block wheels to prevent movement gt Returning vehicle to service 1 Fully recharge batteries Check tire pressure and keep tires inflated to the specifications labeled on the sidewall Readjust if necessary 3 Perform initial maintenance per Service and Maintenance Schedule Chapter 3 Specific Gravity and Freeze Point 1 260 1 230 1 200 1 117 1 110 Gravity Freezing F C F C F C F C F C Point of 70 57 39 38 16 26 2 19 17 8 Electrolyte Figure 4 Freezing point of batteries Chapter 3 MAINTENANCE AND SERVICE PAGE Maintenance Guidelines 3 3 Checklist 3 3 Troubleshooting Hints 3 6 General Safety Precautions 3 6 Maintenance Procedures Electrical System 3 7 Motor Brushes Motor Removal Batteries 3 7 Testing Inspection amp Maintenance Removal Battery Charger Charging Batteries Outside Of Vehicle Lamps Fuses amp Flasher 3 12 Drive System 3 12 Drive Chain Adjustment Chain and or Sprocket Replacement M 18 Drive System 3 13 Drive Chain Adjustment Chain and or Spro
78. on available at the time of publication The Service Maintenance operations outlined in this manual are intended only as a guide and highlight major points only It is not intended as a Shop Manual If you need more information regarding a specific item or encounter problems contact your local Columbia Industrial amp Commercial Vehicle Dealer or Columbia ParCar Corp Technical Services GENERAL SAFETY PRECAUTIONS A CAUTION To prevent possible injury always disconnect batteries before performing any maintenance see Safety Precautions for disconnect method A CAUTION To prevent the possibility of a runaway vehicle and or damaged components after work is performed on the drive train speed control or electrical system in general 1 Raise both rear wheels off the ground and block the front wheels Place jack stands as needed 2 Reconnect battery pack positive cable first 3 Test vehicle function s before lowering vehicle to the ground and attempting vehicle operation A CAUTION When replacing any part or fastener use only Columbia Industrial Vehicle replacement parts or parts that are equivalent in terms of rated strength capacity material etc and that are certified for the purpose intended Failure to do so could cause vehicle malfunction and possible personal injury A convenient chart summarizing the frequency of service requirements and the type of maintenance required is included on page 4 Service Maintenance Schedule T
79. out a charge Limit use of new batteries between charges for the first 5 cycles New batteries and older batteries which have been in storage are not capable of their rated output until they have been discharged and charged a number of times During the first month of use particularly when temperatures are below 60 F new batteries should be given an extra full charge once a week The ampere hours of energy those batteries can deliver and the rate at which they charge varies directly with battery temperature Lower temperatures will require lower charge cycles The charge rate will taper down to the specified finish charge rate near the end of the charge cycle and then will shut off automatically cells in a set of batteries do not react identically to the same discharge and charge current In a normal charge the last 1 to 3 hours at the low finish charge rate equalizes these cells for better battery life When batteries age to the point where the charge rate will no longer taper into the low finish rate the batteries should be tested to see if they are nearing the end of their useful life 3 9 BATTERIES cont Add distilled water carefully to the proper level in cells as required only after they have been fully charged Do not fill them so high that they bubble over while charging New batteries require very little addition of distilled water whereas very old batteries may require additional distilled water two or t
80. r back to center position To operate the hazard warning lights pull outward on hazard bar Moving the signal indicator lever to either turn signal position turns off the hazard lights Vehicle Operating Controls 10 Charger Receptacle The charger receptacle is located on the kickpanel by the drivers left leg The AC cord is plugged in here for battery charging Floorpanel A CAUTION DO NOT attempt to recharge batteries with a charger not designed for your vehicle NOTE If a portable charger is provided the receptacle is located on the dash panel The DC cord is plugged in there for battery charging Battery Discharge Indicator and Hour Meter Indicators The Battery Discharge Indicator is located on the support panel in front of the steering wheel column The BDI indicates the batteries state of charge and is to the right of the Hour Meter This item may not be included on all vehicles The Hour Meter is also located on the support panel in front of the steering wheel column It indicates the total number of hours the vehicle has been operating This item may not be included on all vehicles 2 6 Vehicle Operating Instructions A CAUTION Before operating the vehicle always check the following items Should any item malfunction or need adjustment DO NOT operate vehicle until the problem has been corrected Table 1 Pre Operation Checklist tem Procedure 3 Check to assure they
81. rofessionals should repair or service this vehicle Persons doing even simple repairs or service should have working knowledge and experience in general electrical and mechanical repair Follow all procedures exactly and observe all warnings and cautions stated in this manual Use caution and common sense It is also necessary that every individual who will operate this vehicle receive adequate training that assures the safe operation and use of this particular vehicle This manual contains the following major chapters Chapter 1 INTRODUCTION Contains Warnings cautions a description of the Burden Carrier important information about taking delivery of the vehicle and lifting instructions Chapter 2 OPERATOR INFORMATION Provides safety rules and guidelines describes the driver training program explains the operation of each control operating instructions and storage of the Burden Carrier Chapter 3 MAINTENANCE SERVICE Shows a scheduled maintenance checklist lubrication instructions and minor maintenance procedures Chapter 4 ILLUSTRATED PARTS LIST Includes an exploded view illustration and detailed parts list for each assembly or component group that has replaceable parts for the Burden Carrier Chapter 5 ELECTRICAL TROUBLESHOOTING Includes any additional information that we may receive from our vendors on the components of the Burden Carrier and or troubleshooting flowcharts These vehicles are not designed for over the road
82. ry voltage 2 Good Full battery voltage 2 Good charge and or replace batteries Less than full battery voltage check key switch and wire harness Less than full battery voltage accelerator micro switch or micro switch circuit defective Full battery voltage diodes between forward and reverse solenoid defective Less than full battery voltage diodes between forward and reverse solenoids defective or accelerator micro switch defective Less than full battery voltage diodes between forward and reverse solenoids or accelerator micro switch defective If low or no voltage check cables and cable connections from controller M to reverse solenoid large side terminal If low or no voltage replace defective forward solenoid If low or no voltage check cables and cable connections from forward solenoid small bottom terminal to motor S 1 If low or no voltage check cables and cable connections from motor S 2 terminal to reverse solenoid small bottom terminal Less than full battery voltage replace defective reverse solenoid M 18 Drive System Keyswitch Battery Discharge Optional Indicator Hour Meter Seat Switch fee au W e Keri Potbox w Q o o BE M Auto Reset Polyfuse 12 Volt Tap Speed Controler Color Code Resistor Reverse Buzzer All unspecified Cables are Black
83. s A in increased speed beyond factory specifications could result in severe personal injury or death Always wear safety glasses or approved eye protection while servicing WARNING gt Exceeding rated vehicle load capacities could result in possible severe gt Always turn key switch to OFF remove key block tires and disconnect the battery negative cable before performing any vehicle service to avoid accidental start up of vehicle and possible injury gt HOT DO NOT attempt to service hot motor or resistors Failure to observe this warning could result in severe burns A gt Cautions appear throughout this manual indicating possible hazards or unsafe practices that may result in minor personal injury damage to vehicles or property CAUTION NOTES gt Notes appear throughout this manual to provide key information to assure procedures are more easily understood or implemented Vehicle Description and Specifications The Burden Carrier is a two passenger vehicle involving cargo hauling operation This vehicle is designed to be driven on smooth surfaces in and around industrial plants nurseries institutions motels mobile home parks resorts etc This vehicle is not designed to be driven on public highways The Burden Carrier travels on level surfaces at a maximum rated speed of 8 to 20 mph depending upon vehicle battery voltage Do not exceed this maximum rated speed Exceeding this speed may result in steering difficulty
84. support spacers and rod adjustment will not correct the problem Move clevis pin up one hole on speed switch lever Always use new cotter pin when reassembling 5 13 M 18 Speed Control System Operation The M 18 speed control system offers infinitely variable speed control in forward and in reverse This is a highly efficient speed control system in that the pulse modulating controller does not waste battery energy For reduced speeds the controller turns on and off the motor circuit at an extremely high rate of speed For increased speed the controller increases the duration at which the motor circuit is completed then decreases the connection duration for lower vehicle speed The result is a smooth and gradual increase and decrease in speed appropriate to accelerator position This system also uses a potentiometer pot box for accelerator speed control Two six 6 terminal solenoids are used for directional control one four 4 terminal solenoid is used as a main contactor Speed Control Switch Pot Box For details regarding speed control pot box adjustment or repair refer to page 5 10 This section contains information regarding testing and failure diagnosis Warning Raise vehicle per lifting instructions Chapter 2 Support safely on jack stands before proceeding Failure to do so could cause accident and or injury Electrical Operation and Circuits Charging Keep switch Off Accel
85. switch and Forward amp Reverse switch turn key on then place switch in desired position forward or reverse Vehicle Does Not Operate Forward or Reverse Voltmeter positive red lead to battery B terminal Voltmeter negative black lead to battery B terminal Key switch in forward Voltmeter positive red lead to red wire at forward solenoid small terminal Voltmeter negative black lead to battery negative B terminal Key switch in reverse Voltmeter positive red lead to yellow wire at reverse solenoid small terminal Voltmeter negative black lead to battery negative B terminal Key switch in forward depress accelerator pedal Voltmeter positive red lead to red wire at forward solenoid small terminal Voltmeter negative black lead to black wire at forward solenoid small terminal Key switch in forward depress accelerator pedal Voltmeter positive red lead to yellow wire at reverse solenoid small terminal Voltmeter negative black lead to black wire at reverse solenoid small terminal Key switch in forward depress accelerator pedal Voltmeter positive red lead to white wire at main solenoid Voltmeter negative black lead to black wire at main solenoid Key switch in forward depress accelerator pedal Voltmeter positive red lead to white wire at 1 tab terminal of speed control module Voltmeter negative black lead to controller B terminal Key switch in forward do not depress accelerator pedal Voltmeter positive red
86. system problems Vehicle Does Not Operate In Forward Operates Correctly in Reverse Voltmeter positive red lead to battery B terminal Voltmeter negative black lead to battery B terminal Key switch in forward Voltmeter positive red lead to red wire at forward solenoid small terminal Voltmeter negative black lead to battery negative B terminal Key switch in reverse Voltmeter positive red lead to yellow wire at reverse solenoid small terminal Voltmeter negative black lead to battery negative B terminal Key switch in forward depress accelerator pedal Voltmeter positive red lead to red wire at forward solenoid small terminal Voltmeter negative black lead to gray wire at forward solenoid small terminal Key switch in forward depress accelerator pedal Voltmeter positive red lead to yellow wire at reverse solenoid small terminal Voltmeter negative black lead to gray wire at reverse solenoid small terminal Key switch in forward depress accelerator pedal Voltmeter positive red lead to white wire at main solenoid Voltmeter negative black lead to gray wire at main solenoid 5 6 Full battery voltage 2 Good Full battery voltage 2 Good Full battery voltage 2 Good No Voltage Good Full battery voltage 2 Good Less than full battery voltage charge and or replace batteries Less than full battery voltage check key switch and wire harness Less than full battery voltage accelerator micro switch or
87. t affect the stability or that results in increased speed beyond factory specifications could result in severe personal injury or death gt Always remove key and disconnect the battery s before servicing or gt batteries used in gas or electric vehicles can explode Always wear full face shield when working on or near batteries Hydrogen fumes are a natural byproduct of charging and discharging and are extremely explosive Do not smoke Keep sparks and flames away from batteries Battery charging should only be done in a well ventilated area See Batteries chapter 3 for details When working around or servicing batteries use care to prevent an accidental arc which could cause an explosion Use only approved insulated tools remove jewelry such as rings watches chains etc and place an insulating material wood plastic rubber etc over all battery connections BATTERY Is poisonous Contains acid Causes severe burns Avoid contact with skin eyes or clothing Antidotes EXTERNAL Flush with water Call a physician immediately INTERNAL Drink large quantities of milk or water Follow with milk of magnesia or vegetable oil Call a physician immediately EYES Flush with water for fifteen minutes Call physician immediately If any problems are found during scheduled maintenance or inspections DO NOT operate vehicle until repairs are made Failure to make necessary repairs could result in fire property damage severe personal in
88. t from accelerator and depress brake pedal NOTE Never rest your foot on brake pedal while operating the vehicle This wears brake pads creates drag and causes excess battery discharge When parking the vehicle move switch to the Neutral position engage parking brake turn key to OFF and remove A CAUTION Never leave the vehicle until you are fully stopped Set the parking brake positioned the direction switch to Neutral turned the key switch to Off and remove the key if vehicle is left unattended A CAUTION When parking headed downhill turn the front wheel s into the curb or toward the side of the road and engage parking brake T CAUTION When parking headed uphill turn the front wheel s away from the curb and let the vehicle roll back a few inches until the rear of one front wheel gently touches the curb and engage parking brake Vehicle Storage Storage If stored for a prolonged period the batteries should be charged as follows Table 2 Battery storage charging times Storage Temperature Charge at Below 40 F Every 6 months 40 60 F Every 2 months Above 60 F NOTE Batteries self discharge when not in use The specific gravity of the electrolyte should be checked every 6 to 8 weeks using a hydrometer See chapter 3 for further details The batteries should be recharged as necessary to resume specific gravity to fully recharged levels approximately 1 260 Fully charged batteries should be stored
89. t operate check motor brushes and armature See Traction Motor page 3 7 Speed Switch Pot Box Testing Remove white and black lead wires from controller 2 and 3 1 4 tab terminals Switch volt ohm meter to ohms scale Capable of measuring 0 to 100 ohms Connect volt ohm meter leads to white and black wires from controller Do not depress accelerator Leave key in off position Leave ohmmeter leads connected to white and black leads removed from controller 2 and 3 tab terminals Switch ohmmeter to a scale capable of measuring up to 6 000 ohms K ohms Slowly depress accelerator and monitor change 5 16 0 to 50 ohms resistance Good Ohms of resistance should rise gradually to a maximum of 4 500 to 5 500 ohms Greater than 50 ohms refer to Pot Switch Adjustment page 5 12 If adjustment does not correct replace pot switch or speed switch assembly See page 5 11 Tf rise in resistance is erratic or skips as pedal is depressed replace pot switch or speed switch assembly f maximum resistance is less than or greater than 4 500 to 5 500 ohms adjust pot switch to correct Refer to page 5 12 Note Always follow trouble shooting guide in exact order as listed below Performing tests out of sequence will cause inaccurate results and lost time in diagnosing electrical system problems Vehicle Does Not Operate In Forward Operates Correctly in Reverse Voltmeter positive red lead to battery B termina
90. taining about 1 2 inch of clean brake fluid HYDRAULIC SYSTEM Brake Fluid Maintenance cont 4 Bleed right wheel first Open bleeder nipple by rotating it counterclockwise about 1 2 turn With master cylinder full of fluid at all times slowly depress foot pedal repeatedly until fluid flows from bleeder nipple free of air bubbles 5 Add fluid to master cylinder to bring to 1 4 inch from cover Close bleeder nipple Repeat above Add fluid to master cylinder to bring to 1 4 inch from cover Close bleeder nipple Repeat above procedure on left wheel a Do re use fluid 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 6 To purge the hydraulic system of remaining air bubbles remove the bolts securing the caliper mounting bracket Without removing the caliper and pads from the disc rotate the caliper to position the bleed nipple in a vertical position While holding caliper in this position bleed system one last time Figure 9 Bleeder 7 Remount caliper to caliper mounting bracket See Figure 10 WHEEL AND TIRE SERVICE Bleeder Wheel amp Tire Removal 1 Place blocks ahead of and behind the wheels that will remain on ground 2 Slightly loosen lug nuts 3 Place a jack under the side of the vehicle just ahead of the rear wheel or behind the front wheel so it will come in contact with the fr
91. time to time which cover interim engineering changes and supplementary information Service Bulletins should be consulted for complete information on the models covered by this manual To insure the safety of those servicing Columbia Industrial amp Commercial Vehicles and to protect the vehicles from possible damage resulting from improper service or maintenance the procedures followed in this manual should always be followed exactly as outlined Execution of the procedures and trouble shooting tips as outlined will ensure the best possible service from the vehicle s To reduce the chance of personal injury and or property damage carefully observe NOTES CAUTIONS WARNINGS and DANGER recommendations through out this manual See chapter 1 for additional detail PREPARATION FOR SERVICE Proper preparation is very important for efficient service work A clean work area at the start of each job will allow you to perform the repair as easily and quickly as possible and reduce the incidence of misplaced tools and parts Columbia Industrial amp Commercial Vehicks that are excessively dirty should be cleaned before work begins Cleaning will occasionally uncover trouble sources Tools instruments and parts needed for the job should be gathered before work is started Interrupting a job to locate tools or parts is a needless delay Special tools required for a job are listed at the front of each section MODEL IDENTIFICATION Always give the full
92. tive cables 3 Remove battery hold down 4 Remove batteries from vehicle A WARNING Use care not to drop batteries because the case may crack spilling battery acid causing serve burns NOTE Negative battery posts face the vehicle rear and Positive posts face the vehicle front Negative Posts Positive Cable to Main Solenoid Negative Cable to B at Controller Battery Hold Down Positive Posts BATTERIES Installation To install the batteries reverse the removal procedure with the negative cable being attached last AUTOMATIC BATTERY CHARGER A CAUTION When charging your Columbia Industrial amp Commercial Vehicle provide adequate ventilation during the charging cycle Do not allow open flames or sparks near batteries during charging cycle Hydrogen gas is generated during the charging process and can be explosive Automatic Battery Charger Operating Instructions A CAUTION Use this charger only on circuits provided with a maximum of 20 ampere branch circuit protection in accordance with the National Electrical Code ANSI NFPA 70 and all local codes and regulations Improper AC supply circuit protection may result in a fire A WARNING Chargers can ignite flammable materials and vapors Do not use near fuels solvents grain dust or other flammables Batteries generate gasses which can be explosive Keep sparks and open flame away from the batteries No smoking A WARNING To reduce
93. tive forward solenoid small terminal Key switch in reverse depress accelerator pedal Voltmeter No Voltage Full battery voltage diodes positive red lead to red wire at forward solenoid small Good between forward and reverse terminal Voltmeter negative black lead to gray wire at solenoid defective forward solenoid small terminal Key switch in reverse depress accelerator pedal Voltmeter Full battery Less than full battery voltage positive red lead to white wire at main solenoid Voltmeter voltage 2 Good diodes between forward and negative black lead to gray wire at main solenoid reverse solenoids defective or accelerator micro switch defective Key switch in reverse depress accelerator pedal Voltmeter Full battery Less than full battery voltage positive red lead to white wire at 1 tab terminal of speed voltage Good diodes between forward and Vehicle Does Not Operate In Reverse Operates Correctly In Forward control module Voltmeter negative black lead to controller B reverse solenoids or terminal accelerator micro switch defective Key switch in reverse depress accelerator pedal Voltmeter Full battery If low or no voltage check positive red lead to controller B terminal Voltmeter voltage 2 Good cables and cable connections negative black lead to 2 terminal at reverse solenoid from controller M to forward solenoid 2 terminal Key switch in reverse depress accelerator pedal Voltmeter Full battery If
94. unterclockwise until belt is correctly tensioned see Figure 6 The belt should deflect 1 8 to 1 4 when pressed down at the middle of the span see Figure 6 4 Tighten motor mounting bolts 35 ft lbs and re check belt tension 5 Replace the belt cover Adjuster AM Figure 6 Belt Tension Belt and or Sprocket Replacement 1 Remove belt cover 2 Loosen the 4 motor mounting bolts 3 Rotate the adjuster cam allowing the motor to move downward relieving tension on belt 4 The belt may now be removed by lifting it off of the sprockets 5 Remove yoke nut lower drive sprocket 6 Note Always replace yoke nut when reinstalling 7 Thelower sprocket may be replaced by removing the four sprocket mounting bolts 8 Theupper sprocket may be replaced by loosening all capscrews in the sprocket hub and thread capscrews into tappered holes in mating part to jack bushing flange 9 Loosen setscrews to slide bushing 10 To install make sure tappered surface of bushing and bore of mating part are clean 11 Install shaft key 12 Slide bushing on shaft flange first snug setscrew against screw 13 Note Excessive torque will cause mating part to eccentric 14 Using a torque wrench tighten capscrews evenely and progressively in rotation to 9 ft Ibs 100 in Ibs 15 After the required parts have been replaced follow steps 3 through 6 under Drive Belt Adjustment Lower Sprocket Figure 7 Pulling I
95. use They do not conform to Federal Motor Vehicle Safety Standards or EPA regulations and are not equipped for operation on public streets roads or highways To the best knowledge of Columbia ParCar Corp the material contained herein is accurate as of the date this publication was approved for printing Columbia ParCar Corp is not liable for errors in this manual or for incidental or consequential damages that result from the use of the material in this manual Columbia ParCar Corp reserves the right to change specifications equipment or designs at any time without notice and without incurring obligation This manual contains proprietary information that is protected by copyright All rights are reserved No part of this manual may be photocopied reproduced or translated to another language without the written consent of Columbia ParCar Corp CHAPTER 1 Introduction Dangers Warnings Cautions amp Notes Vehicle Description amp Specifications Upon Delivery of your Vehicle Lifting Instructions Page DANGERS WARNINGS CAUTIONS AND NOTES Statements in this manual proceeded by the words DANGER WARNING CAUTION or NOTE and printed in bold face are very important We recommend you take special notice of these items It is important to note that some warnings against the use of specific service methods which could damage the vehicle or render it unsafe are stated in this service manual However please remember that these
96. ve Full battery voltage diodes between forward and reverse solenoid defective Less than full battery voltage diodes between forward and reverse solenoids defective or accelerator micro switch defective Less than full battery voltage diodes between forward and reverse solenoids or accelerator micro switch defective Less than full battery voltage accelerator micro switch or micro switch circuit defective Full battery voltage diodes between forward and reverse solenoids are defective Less than full battery voltage diodes between forward and reverse solenoids defective or accelerator micro switch defective Less than full battery voltage low batteries poor or corroded connections Key switch in forward do not depress accelerator pedal 1 to 5 voltsless No voltage defective resistor 5 4 Vehicle Does Not Operate Forward or Reverse than full battery If full battery voltage replace welded main solenoid Voltmeter positive red lead to main solenoid 1 terminal Voltmeter negative black lead to controller B terminal voltage 2 Good Key switch in forward depress accelerator pedal Voltmeter positive red lead to main solenoid 1 terminal Voltmeter negative black lead to controller B terminal Key switch in forward depress accelerator pedal Voltmeter positive red lead to traction motor A 1 terminal Voltmeter negative black lead to controller B terminal Key switch in forward depress
97. vehicle identification number when ordering parts or making inquiries about your Columbia Industrial amp Commercial vehicle Use of the full and complete vehicle identification number VIN information will assure your dealer or service provider is supplying you with the correct parts for your vehicle See chapter 1 for vehicle identification information USE GENUINE REPLACEMENT PARTS A WARNING When replacement parts are required use only genuine Columbia Industrial amp Commercial Vehicle parts or parts with equivalent characteristics including type strength and material Failure to do so may result in product malfunction and possible injury to the operator and or passenger To ensure a satisfactory and lasting repair job follow the service manual instructions carefully and use only genuine Columbia Industrial amp Commercial Vehicle replacement parts This is your insurance that the parts you are using will fit right operate properly and last longer When you use genuine Columbia Industrial amp Commercial Vehicle parts you use the best PRODUCT REFERENCES When reference is made in this manual to a specific brand name product tool or instrument an equivalent product tool or instrument may be used in place of the one mentioned Table of Contents CHAPTER 1 INTRODUCTION Warnings amp Dangers Vehicle Description amp Specifications Upon Delivery of Your Vehicle Inspecting the Vehicle What to do if you Find a Probl
98. verse solenoid If low or no voltage check cables and cable connections from motor S 2 terminal to forward solenoid small bottom terminal Less than full battery voltage replace defective forward solenoid Note Always follow trouble shooting guide in exact order as listed below Performing tests out of sequence will cause inaccurate results and lost time in diagnosing electrical system problems Vehicle Does Not Operate In Reverse Operates Correctly In Forward Voltmeter positive red lead to battery B terminal Voltmeter Full battery Less than full battery voltage negative black lead to battery B terminal 1 Key switch in forward Voltmeter positive red lead to red wire at forward solenoid small terminal Voltmeter negative black lead to battery negative B terminal 2 Key switch in reverse Voltmeter positive red lead to yellow wire at reverse solenoid small terminal Voltmeter negative black lead to battery negative B terminal Key switch in reverse depress accelerator pedal Voltmeter positive red lead to yellow wire at reverse solenoid small terminal Voltmeter negative black lead to black wire at forward solenoid small terminal Key switch in reverse depress accelerator pedal Voltmeter positive red lead to red wire at forward solenoid small terminal Voltmeter negative black lead to black wire at forward solenoid small terminal Key switch in reverse depress accelerator pedal Voltmeter positive red lead
99. warnings are not all inclusive Since Columbia Industrial Vehicle could not possibly know evaluate and advise servicing personnel of all possible ways in which service might be done or of the possible hazardous consequences of each way we have not undertaken any such broad evaluation Accordingly anyone who uses a service procedure or tool which is not recommended by Columbia Industrial Vehicle must first thoroughly satisfy himself that neither his nor the operator s safety will be jeopardized by the service methods selected A DANGER Danger indicates an immediate hazard that will result in severe personal injury or death A WARNING Warnings will indicate an immediate hazard which could result in severe personal injury A CAUTION Cautions indicate hazards or unsafe practices which could result in minor personal injury damage to the vehicle or to other property NOTE Notes will provide key information to assure procedures are more easily understood or implemented It is Columbia Industrial Vehicle s specific recommendation that the following warnings must be observed at all times Not all are repeated throughout this manual but the recommendations included must be observed whenever these subjects indoor vehicle operation hazards gasoline and fuel system hazards battery hazards etc are encountered Be a safe operator Electric Industrial vehicles are only as safe as the person who is at the controls If accidents are to be prevent
100. xtension Not Pictured in Illustration 6 aan 8 EN ET 4 23 M18 Electrical Wiring BC3 30 BC4 25 BC3 30XB BC4 25XB 18 Keyswitch Battery Discharge Optional Indicator Hour Meter 1 9 15 Seat Switch 20 23 MN RTT ES Auto Reset Polyfuse 16 R 12 Voit gt 16 1 J 9Pin Connector 14 12 8 ree Reverse Buzzer Auto Reset Polyfuse x 11 13 D 1 MOTOR 52 4 25 M18 Drive System BC3 30 BC4 25 BC3 30XB BC4 25XB Item Description Plate M18 Motor Mount Belt Toothed 960T Sprocket Belt 40T 6384 02 Bushing 7 8 For 40T Sprocket 3481 02 Cover M18 Drive 6386 02 Sprocket Belt 56T 401 00 Motor Traction 36 48 980 01 Axle M18 12 25 1 2853 95 Bracket Axle Bracket Mounting LH Brake 1266 00 Bracket Mounting RH Brake 038 B Lockwasher 3 8 3420 00 Washer Chain Adjuster 716 W Screw Hex Cap 3 8 16x1 1 4 416 Washer Type A Plain 3 8 1207 Key Parallel 3 16 Sqx2 20 B Screw Black Zinc 3 8 16x1 3 4 78 Locknut Nylok 3 8 16 538 Locknut Flange 5 16 18 036 B Washer 872 W Screw Hex Cap 1 4 20x1 1 2 551 W Screw Hex Cap 1 4 20x1 Cover Mounting 703 B Washer Type A 1 4 Cover Mounting Locknut Nylok 1 4 20 Cover Mounting Screw Hex Cap 3 8 16X1 Plate to Axle Not Pictured in Illustration o gt i lt NIN AINA o
101. y Frame Complete 62 Bed xg 19501 00 Body Frame Complete 76 Bed PENES 3 79 00 Cover atery Commen 51320 00__ Deckboard Short 5 51323 00 Cover Deckboard Long 51321 00__ Deckboard Long 6 1600 Bolt Flat Lifting 5 16 18x2 1 2 8 51701 00__ Seat Assy LH Complete With switch 9 518525400 Seathoard 1 10 Tomum _ 7739 Locknut Nylok 5 16 18 Seat Mounting 81 6000 B_ Washer 5 16 Seat Mounting 818 12 68860 00__ Signal Turn Kit AAA 13 48880 77 Windlace Trim Order by foo Plug 2 3 32 When Hour Meter is not used HHH Plug 3 When Battery Discharge Indicator is not used HHEH Steering Wheel 4 3 Front Axle amp Suspension Front Axle amp Suspension Part Description ront Suspension Group 827 00 ssembly Axle Beam tting Grease Axle ssembly Spindle LH ssembly Spindle RH shing Kingpin 6843 00 ssembly Kingpin ut Kingpin asher Thrust earing Thrust 1100 Ring ssembly Spring 4 Leaf ssembly Spring 6 Leaf 54819 00 ssembly Spring 7 Leaf Bolt Front Axle 1 2 13x5 1 4 4 Leaf Spring U Bolt Front A xle1 2 13x5 7 8 6 amp 7 Leaf Spring late Spring to Front Axle Nut Hex 12 13 U Bolt to Spring Lockwasher 1 2 U Bolt to Spring 4801 00 Shackle Spring to Frame Bushing Spring to Frame Spacer Spring to Frame Screw Hex Cap 3 8 16 x 3 3 4 Spring to Frame Locknut 3 8 1
102. y sliding off rotor Do not disconnect hydraulic line from caliper 5 Slide the caliper carrier out from the caliper housing exposing the brake pads 6 Remove brake pads from caliper dead side housing and from pistons Figure 9 Rear Brake DO NOT remove pistons from caliper housing Caliper Assembly 7T Whenreplacing brake pads push into housing 8 Re assemble by reversing steps 1 through 7 using new brake pads 9 Usecaution when remounting the brake calipers Tighten each of the 5 16 bolts gradually alternating from one to the other As you tighten the bolts be certain that the pads are parallel to the disk if they are not a spongy brake pedal may result Also be sure that the caliper can still move back and forth in the caliper housing mounting if it can t uneven pad wear will result 10 If rear brake pads are replaced adjustment of park brake will be necessary See Handbrake Parkbrake Arm Adjustment 11 Reinstall wheel and tire Tighten the lug nuts evenly in a star pattern until the nuts are all seated and torque to 50 60 ft Ibs NOTE Do not press on the brake pedal when the disc brake pads are not in place Rotor Replacement Front Wheel A CAUTION Disconnect batteries and block rear wheels and raise front of vehicle off the ground See Chapter 1 for lifting instructions 1 Remove wheel and tire 2 Remove parkbrake cable from park brake arm on the caliper 3 Remove the two 5 16 bolts from t

Chapter 2 - Columbia ParCar Corp.

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