Columbia ParCar Expediter EX21-24S Service Manual
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Columbia ParCar Expediter EX21-24S Service Manual

Columbia ParCar Expediter EX21-24S Service Manual

Designed to be driven over smooth surfaces in and around places such as warehouses and factories.
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Columbia ParCar Corp.
SERVICE MANUAL
Expediter™
EX21-24S
EX21-24A
EX21-48A
2013

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Summary of Contents for Columbia ParCar Expediter EX21-24S

  • Page 1 Columbia ParCar Corp. SERVICE MANUAL Expediter™ EX21-24S EX21-24A EX21-48A 2013...

  • Page 2: Table Of Contents

    In addition to the information given in this manual, Service Failure to do so could result in product malfunction and Bulletins are issued to Columbia ParCar dealers which cover possible injury to the operator and/or passenger. interim...
  • Page 3 Table of Contents Tools Required ............. 3-3 Hoist Removing Steering Wheel ........6-3 Lifts .............. 3-4 Replacing Steering Shaft Bearings ....... 6-3 Hoisting the Rear of Vehicle ......... Installing Steering Wheel ........6-3 Hoisting the front of Vehicle ........Upper Steering Group ........... 6-3 Disassembly ............
  • Page 4 Table of Contents Battery Service (Water) ........9-2 Battery Charger ............. 9-9 Adding Water ............Removal ..............Single Point Watering System ......9-2 Installation ............. 9-9 Battery Charging ........... 9-3 SECTION 10 – TRACTION DRIVE SYSTEM Charger Safety Information ........Battery Brand Algorithms ........

  • Page 5: Section 1 - Safety

    However, please remember that these warnings are not all inclusive. Since Columbia ParCar Corporation could not possibly know, Warning indicates a hazardous situation which, if not evaluate and advise servicing personnel of all possible ways in avoided, could result in death or serious injury.

  • Page 6: Safety Information

    Accordingly, anyone who uses a service procedure or tool chains, etc. and place an insulating material such as which is not recommended by Columbia ParCar must first wood, plastic, rubber, etc. over batteries covering all thoroughly satisfy him/herself that neither their nor the connections.

  • Page 7: Safety Preparations

    Working Columbia ParCar vehicles without following proper procedures and using proper lifting equipment may result in vehicle damage or personal injury. See Section 3 - Lifting Instructions detailed instructions. Always wear safety glasses or approved eye protection while servicing vehicle. Wear a full face shield when working with batteries.

  • Page 8: Section 2 - General Information

    Service Manual Section 2 General Information...

  • Page 9: Vehicle Description

    VEHICLE DESCRIPTION Section 2 – General Informatio n remove nameplate, warnings, instructions affixed to your Columbia Industrial Vehicle. Promptly replace any that become damaged or removed. The EX-21 Expediter is an electric three or four wheel vehicle. It is designed for one person and load or two persons (one facing the rear).

  • Page 10: Safety Committee

    21.5 x 26.0 (in) These basic rules of operation, combined with courtesy and Weight (lbs) 1100 1183 common sense, will help make driving your Columbia ParCar Vehicles a safe and pleasant experience. Rated Capacity 750 lbs. Towing Capacity 1000 lbs.

  • Page 11: Vehicle Controls

    Section 2 – General Information C - SYSTEM STATUS LIGHT Motor Braking Regenerative & accelerator pedal Mode proportional D - HORN BUTTON Directional Fully electronic direction switching Control with console selector switch E - LIGHT SWITCH (option) Automotive style, helical gears in oil Drive Unit bath, direct to motor F - BATTERY DISCHARGE METER (BDI) G - HOUR METER...

  • Page 12: Pre-Operation Inspections

    Section 2 – General Information PRE-OPERATION INSPECTIONS Each vehicle has been inspected and adjusted to factory Should any item malfunction or need adjustment. Do not specifications before delivery. Upon receipt of vehicle, perform a operate vehicle until the problem has been corrected. predelivery inspection of the vehicle.
  • Page 13 Section 2 – General Information...

  • Page 14: Section 3 - Maintenance

    SemiAnnual or Annual maintenance, ensure that Daily and Weekly inspections are included. A comprehensive maintenance program is important for the safe, reliable operation of all Columbia ParCar vehicles. The NOTICE: The environment that the vehicle operates in recommended procedures described in this service manual are can vary widely.
  • Page 15 Section 3 – Maintenance NOTICE: Daily maintenance performed daily before operation of vehicle by owner operator. Weekly maintenance performed weekly basis to include all daily maintenances and is performed by the owner, operator or trained maintenance personnel. MAINTENANCE SCHEDULE CHECKLIST – BODY/FRAME/CHASSIS Quaterly Semi-annual Component...
  • Page 16 Section 3 – Maintenance Clean terminals and wash battery case Test batteries Electrical Check for tightness wires or damage Reverse Check for operation warning (use keyswitch) buzzer † Service done by trained maintenance personnel * Service done by Owner MAINTENANCE SCHEDULE CHECKLIST - TIRES &...

  • Page 17: Batteries

    Section 3 – Maintenance MAINTENANCE SCHEDULE CHECKLIST – ELECTRIC MOTOR Quaterly Semi-annual Component Procedure Daily Weekly Monthly Annual (25 Hours) (50 Hours) Test drive for proper Operation operation Inspect brush length & remove carbon dust Inspect Motor & apply anti-seize to splines Service done by owner.

  • Page 18: Hoisting The Rear Of Vehicle

    Section 3 – Maintenance If a hoist is used to lift the vehicle, check that the hoist is rated at a capacity greater than the vehicle weight. Lift the vehicle sufficiently from the floor, 10° to 25° angle, to allow the placement of jack stands to support the weight of the vehicle during service.
  • Page 19 Section 3 – Maintenance The specific gravity of the electrolyte should be checked every 6 to 8 weeks and charge as necessary to maintain 1.250 to 1.270 specific gravity.

  • Page 20: Returning Vehicle To Service

    Section 3 – Maintenance RETURNING VEHICLE TO SERVICE: Reconnect battery negative terminal. Batteries in a low state of charge will freeze at higher Fully recharge batteries and check fluid levels. temperatures than fully charged batteries. Do not For vehicles with a single point watering system: After the attempt to charge a battery that is frozen or if battery batteries have been fully charged, connect the system to case is excessively bulged.
  • Page 21 use the following Torque Table as a general guide in determining proper torque. When a metric equivalent is not listed, use the Conversion Factors Chart to convert to metric values. Conversion Factors Chart...
  • Page 22 Into Metric Out of Metric to convert from Multiply by to convert from Multiply by Work force measurements inch-pound N. m. 0.1130 Newton-meter in. lb. 8.8496 foot-pound N. m. 0.3558 Newton-meter in. lb. 0.7376 Length Measurements inch 25.4 millimeter 0.0394 foot 0.3048 meter...

  • Page 23: Pre-Troubleshooting Steps

    Service Manual Section 4 Troubleshooting Always turn keyswitch to OFF and remove. Directional knob to Neutral, block tires and disconnect the battery negative (-) cable before performing any vehicle service to avoid accidental startup of vehicle and possible injury. PRE-TROUBLESHOOTING STEPS Before troubleshooting a vehicle for any problem or symptoms, certain steps must be followed.

  • Page 24: Troubleshooting Specific Complaints

    Section 4 - Troubleshooting Perform a visual examination of batteries and The batteries can be cleaned by hose washing with a standard garden connections. Examine for signs of corrosion and hose or with a soft bristle brush (ensure battery caps are present and clean/or replace any affected terminals or cables.
  • Page 25 Section 4 - Troubleshooting Open the connection between the controller and the PCPaK utility. On the left side of the screen, select the “test” section under the “traction” pull down. This screen will display the inputs the controller is observing at that time (Figure 4-3).
  • Page 26 Section 4 - Troubleshooting TROUBLESHOOTING WITH PCPAK (continued) Check the FS1 Switch input on the same screen. With the accelerator at rest, the value for the FS1 Switch should read “open”. When the accelerator pedal is pressed, the value should change to “closed” (Figure 4-5). If the value fails to close, check the FS1 wiring circuit and test the switch with a VOM.
  • Page 27 Section 4 - Troubleshooting Figure 4-7...

  • Page 28: Troubleshooting With Handheld Calibrator

    Section 4 - Troubleshooting TROUBLESHOOTING WITH THE HANDHELD CALIBRATOR Connect the handheld calibrator to the vehicle and enter the “Read-Only” mode (RON). Scroll down by pressing “Select” button until you reach the “19” menu (location Check the direction input to the controller. Observe the 19.01).

  • Page 29: Vehicle Drives Slowly

    Section 4 - Troubleshooting VEHICLE DRIVES SLOWLY ▪ New brushes are square cut . Check for all physical/visual signs of damage, low tire Brushes will “seat - in” with a pressure or jammed linkages. slight curve ▪ Check for brake drag by turning vehicle power off, releasing parking brake, and attempting to roll vehicle a short distance.

  • Page 30: Flash Codes And Corrective/Investigative Action

    Section 4 - Troubleshooting FLASH CODES AND CORRECTIVE/INVESTIGATIVE ACTION Handset Correction – Calibrator Flash Code Description Action ID fault reference loc If fault does not clear number Disconnect any Controller replacement required, Internal Mosfet failure electrical accessories 25 / 26 13.01 0 Flash (Light contact Tech Support...

  • Page 31: Component Troubleshooting

    Section 4 - Troubleshooting Pedal depressed at start Ensure Accelerator Repair or replace failed Pedal returns to 0 (rest) 8 or 9 13.01/19.01/19.07 connection or component position FLASH CODES AND CORRECTIVE/INVESTIGATIVE ACTION (CONTINUED) Handset Calibrator Correction – Flash Code Description Action ID fault reference...
  • Page 32 Section 4 - Troubleshooting Battery Discharge Indicator (BDI) ▪ ▪ Open wiring or failed connection. Check wiring and Fuse failed. Check fuse and replace if failed. connections. ▪ Open wiring or failed connection. Check wiring and ▪ Inoperable reverse buzzer. Replace buzzer. connections.

  • Page 33: Section 5 - Accelerator & Brake System

    Service Manual Section 5 Accelerator & Brake System MECHANICAL BRAKE SYSTEM GENERAL The mechanical braking system consists of two rear wheel drum brakes, the brake pedal, springs and brake linkage to Always turn keyswitch to OFF and remove. Turn operate the brakes. direction knob to Neutral, block tires and disconnect the battery negative (-) cable before performing any These brakes are self-adjusting and should not require...

  • Page 34: Periodic Brake Inspection

    Section 5 - Accelerator & Brake System PERIODIC BRAKE INSPECTION contact points between brake shoe and brake back plate. Remove excess grease prevent brake shoe Intervals between brake service and inspection may vary contamination. depending on driving habits, type of driving, road and climate conditions, and vehicle load Do not use compressed air to blow dust from brake assembly.
  • Page 35 Section 5 - Accelerator & Brake System Figure 5 - 2 Figure 5-1...

  • Page 36: Brake Drum Service 1

    Section 5 - Accelerator & Brake System BRAKE DRUM SERVICE 1. into slots on automatic adjuster screw and opposing retainer. Next, hook top end of each brake shoe behind Rebore or replace anchor at the top of brake plate. Fold ends of shoes inward towards brake plate.

  • Page 37: Mechanical Brake Adjustments

    Section 5 - Accelerator & Brake System Remove cotter pin and clevis pin securing brake strips to brake cross member. Discard cotter pin and e-ring. Repeat for other brake strips. Secure brake strips to rear axle brake actuator arms (Figure 5-4) with new clevis pins and new cotter pins. Secure brake strips to brake cross member with new clevis pins and new cotter pins.

  • Page 38: Drum Brake Shoe Adjustment

    Section 5 - Accelerator & Brake System Depress the parking brake pedal until the first click is heard. At this setting the vehicle should not roll when on a slight incline. Depress the pedal to the second click, or notch. With the parking brake set, the vehicle should not roll on a steep incline or hill.

  • Page 39: Section 6 - Front Wheels, Fork & Steering

    Service Manual Section 6 Front Wheels, Fork & Steering Always turn Power keyswitch to OFF, Directional knob to Neutral, remove Power keyswitch, block tires and disconnect the battery negative (-) cable before performing any vehicle service to avoid accidental startup of vehicle and possible injury.

  • Page 40: General

    Section 6 – Front wheels, Fork & Steering GENERAL Three wheel models utilize a suspension mount front fork or a non-suspension front fork. Both can be coupled with either a loop tiller control bar, a handle control bar or steering wheel with a rack and pinion steering assembly.

  • Page 41: Inspecting/Replacing Wheel Hub Bearings

    Section 6 – Front wheels, Fork & Steering Figure 6-3 INSPECTING/REPLACING WHEEL HUB BEARINGS NOTICE: If bearing appears worn, or steering is not smooth, continue with steps 3 - 5 and replace the ROLLER BEARINGS bushing and bearings (Figure 6-4). Roller bearings should be replaced whenever wheel hub is REPLACING STEERING SHAFT BEARINGS removed.
  • Page 42 Section 6 – Front wheels, Fork & Steering On 3-wheel models, use a soft mallet to tap the steering shaft and front fork assembly free of the steering column. To perform this service, raise vehicle using floor jack Grease new bearings and tap into steering column. and safely support it with jack stands positioned under Re-install steering shaft and washers.

  • Page 43: Installing Tiller

    Section 6 – Front wheels, Fork & Steering INSTALLING TILLER INSTALLING STEERING WHEEL Make sure wheels are pointed straight ahead. Make sure wheels are pointed straight ahead. Apply Anti-Seize to steering shaft. Install square key and Apply Anti-Seize to steering shaft. Install steering wheel tiller on steering shaft and torque to 22-25 ft.
  • Page 44 Section 6 – Front wheels, Fork & Steering Install steering column guard.
  • Page 45 Section 6 – Front wheels, Fork & Steering Figure 6 - 5...
  • Page 46 Section 6 – Front wheels, Fork & Steering...

  • Page 47: Front Suspension Fork - 3 Wheel

    Section 6 – Front wheels, Fork & Steering NOTICE: If tie rod ends are to be replaced, take note of the tie rod end studs orientation. Use a felt tip marker to mark these directions on the ends of the steering Figure 6-6 shaft and tie rods as an aid for reassembly.
  • Page 48 Section 6 – Front wheels, Fork & Steering Figure 6 - 8 For short tie rod, disconnect tie rod end from steering Replace parts as necessary. Install new tie rod end and/or shaft. Take note that tie rod end is left-hand thread. tie rod ends in same as orientation as previously marked.

  • Page 49: Replacing Bushings

    Section 6 – Front wheels, Fork & Steering REPLACING BUSHINGS (Figure 6-8) Remove front wheels. Remove tie rods as described previously in Tie Rod Replacement. Remove screw, washers and lock nut securing axle retaining plate to axle support. Remove screw and jamnut securing trunnion to axle support.

  • Page 50: Section 7 - Rear Wheels, Rear Suspension & Axle Assembly

    Section 6 – Front wheels, Fork & Steering Service Manual Section 7 Rear Wheels, Rear Suspension & Axle Assembly...
  • Page 51 Section 6 – Front wheels, Fork & Steering 2013 EX-21 Service Manual...

  • Page 52: Rear Wheels

    Section 7 - Rear Wheels, Rear Suspension & Axle Assembly TIRES In the event of a flat tire, remove wheel assembly from vehicle and follow standard tire repair procedures. Always turn power key to off, directional keyswitch to neutral, remove power key, block tires and disconnect REAR SUSPENSION the battery negative (-) cable before performing any vehicle service to avoid accidental startup of vehicle...

  • Page 53: Rear Axle Assembly

    Section 7 - Rear Wheels, Rear Suspension & Axle Assembly Figure 7 - 1 REAR AXLE ASSEMBLY Remove rear shock absorbers and springs as described...

  • Page 54: Removing Rear Axle

    Section 7 - Rear Wheels, Rear Suspension & Axle Assembly on the previous page. To perform this service, raise vehicle using floor jack and safely support it with jack stands positioned under main frame tubes. See Section 3 Maintenance - Lifting Instructions.

  • Page 55: Torques

    Section 7 - Rear Wheels, Rear Suspension & Axle Assembly ● Bearings, seals and O-rings should be replaced with new Cover plate screws 16-24 ft.lbs. parts whenever they are removed. Always wipe seals and Fill plug 25-40 ft.lbs. O-rings with SAE 30 oil before installing. Brake bolts ●...
  • Page 56 Section 7 - Rear Wheels, Rear Suspension & Axle Assembly Figure 7 - 4...
  • Page 57 Section 7 - Rear Wheels, Rear Suspension & Axle Assembly Figure 7 - 6...

  • Page 58: Disassembling Rear Axle

    Section 7 - Rear Wheels, Rear Suspension & Axle Assembly Figure 7-5 DISASSEMBLING REAR AXLE Safety glasses should be worn at all times when disassembling and assembling the axle. Figure 7 - 7 All callout numbers in steps refer to Figure 7-4. Remove outer snap ring (25).
  • Page 59 Section 7 - Rear Wheels, Rear Suspension & Axle Assembly Figure 7-8 a guide. Figure 7 - 9 Figure 7 - 12 Figure 7 - 10 Figure 7 - 13 Figure 7 - 11 Figure 7 - 14 10. Using a bearing puller, remove differential bearings (8) from each side of the differential case.
  • Page 60 Section 7 - Rear Wheels, Rear Suspension & Axle Assembly...
  • Page 61 Section 7 - Rear Wheels, Rear Suspension & Axle Assembly Figure 7 - 15 Figure 7 - 17 Figure 7 - 1 6 Punch or drill a 1/8” diameter hole near the center of each intermediate cup plug (17). Insert a suitably sized sheet metal screw until the metal bore plug is forced out Figure 7 - 18 of the bearing bore.

  • Page 62: Assembling Rear Axle

    Section 7 - Rear Wheels, Rear Suspension & Axle Assembly Remove O-rings from outer input bearing bore and both input shaft bore (12). See Figure 7-17. intermediate bores. See Figure 7-19. Remove O-rings (10) at each end of intermediate shaft NOTICE: Input shaft assembly must be supported by on bearing shoulders.
  • Page 63 Section 7 - Rear Wheels, Rear Suspension & Axle Assembly To seat the bearing past the O-ring, a leather or plastic mallet may be required. NOTICE: Intermediate shaft assembly must supported by hand as not to damage gear teeth. Use care if using a hammer to coax shaft and gear into correct position.
  • Page 64 Section 7 - Rear Wheels, Rear Suspension & Axle Assembly Position differential case assembly (4) with flanged side trunnion face down on work surface. Align output gear (5) mounting holes with differential case. Install four bolts (6) and nuts (7). Bolts should be installed from differential flange side.

  • Page 65: Installing Rear Axle

    Section 7 - Rear Wheels, Rear Suspension & Axle Assembly 21. Remove fill plug (19) in cover plate (18). Fill axle assembly with 12 ounces (360 ml) of Light Weight Gear Lubricant, SAE 30. Install fill plug. If it is a threaded plug, torque to 25-40 ft. lbs.
  • Page 66 Section 7 - Rear Wheels, Rear Suspension & Axle Assembly To perform this service, raise vehicle using floor jack and safely support it with jack stands positioned under main frame tubes. See Section 3 Maintenance - Lifting Instructions. Have an oil drain pan handy. Remove ten cover plate bolts (Figure 7-32).
  • Page 67 Section 7 - Rear Wheels, Rear Suspension & Axle Assembly...

  • Page 68: Section 8 - Body & Chassis

    Service Manual Section 8 Body and Chassis Always turn power key to off, directional keyswitch to neutral, remove power key, block tires and disconnect the battery negative (-) cable before performing any vehicle service to avoid accidental startup of vehicle and possible personal injury.

  • Page 69: Front Bumper

    FRONT BUMPER The front bumper attaches to the body with three bolts, washers and nuts (Figure 8-1). HORN The horn is mounted under the front of the body. It is secured to a rubber bumper stud with a 1/4-20 nut. CARGO DECK The deck plate assembly (plywood deck) is not attached to the vehicle but rests in the recess of the body.

  • Page 71: Horn Button

    Section 8 – Body and Chassis HORN BUTTON Remove wires from back of horn button. Remove retainer nut from front of button and remove it. Connect wires to new horn button and install it with retainer nut. SEAT Tilt the seat forward to gain access to the battery compartment.
  • Page 72 Figure 8-6...

  • Page 73: Important Information

    Service Manual Section 9 Battery and Battery Charger IMPORTANT INFORMATION All batteries used in electric vehicles can explode! The type of battery used in a Columbia vehicle has a service Always wear full face shield when working on or near requirement which is quite different from that of an automotive batteries.

  • Page 74: Antidotes

    Section 9 – Battery and Battery Charge Remove battery cables and wire connections from all battery terminals. When working around batteries, approved insulated tools, remove jewelry such as rings, watches, Brush battery cable and wire connections clean using soft chains, etc. and place an insulating material such as brass wire brush.

  • Page 75: Single Point Watering System

    Section 9 – Battery and Battery Charge ▪ Never allow the electrolyte level to fall below the top of the plates (A). If the plates are exposed, add only enough distilled water to cover the plates before charging. ▪ Do not overfill batteries. Do not fill the water level up into the well of the filler tube of the cell.

  • Page 76: Battery Charging

    Section 9 – Battery and Battery Charge BATTERY CHARGING ▪ Charge batteries in well ventilated area. ▪ Ventilation fans should be located at the highest point in Observe all safety information in this section, safety charging area. These fans should be able to exchange the air 5x per hour.

  • Page 77: Battery Brand Algorithms

    Section 9 – Battery and Battery Charge BATTERY BRAND ALGORITHMS Table 1 ALGORITHM ALGORITHM TYPE DESIGNED FOR COMPATIBLE WITH DESCRIPTION HOUR 150 - 260Ah 6V, 8V, 12V flooded Trojan Flooded Flooded Trojan T105 golf Trojan Constant Power 150 - 260Ah 6V, 8V, 12V flooded Flooded Trojan T105 dv/dt...

  • Page 78: Single Led Display

    Section 9 – Battery and Battery Charge with an equipment-grounding AC electric cord, and a on as the last 20% of charge is returned to the batteries in grounding type plug. the second phase (constant voltage phase). NOTICE: You can terminate charging at this point if Connect the cord to an appropriately installed receptacle necessary.

  • Page 79: Hydrometer Test

    Section 9 – Battery and Battery Charge 1 Flash to half scale or does not rise at all, check AC outlet for proper power supply or check charger owner’s manual for Battery Voltage High: Auto-recover. May be temporary testing and repair information. condition, or wrong charger installed, i.e.

  • Page 80: Discharge (Load) Test

    Section 9 – Battery and Battery Charge ▪ Vehicle must not be used, even for short runs, prior to 1.250 – 1.270 100% Discharge (Load) Test. 1.220 – 1.240 ▪ Electrolyte level must be correct in all cells. 1.190 – 1.210 TEST PROCEDURE 1.160 –...

  • Page 81: Excessively Discharged Batteries

    Section 9 – Battery and Battery Charge on the plates during discharge is relatively insoluble as long as Electrolyte Temperature (Step Minimum Discharge Time the specific gravity of electrolyte is kept above 1.125 specific (Step 5) gravity, but if allowed to drop below this value, the lead sulfate 40-49 F (4-9 40 Minutes...

  • Page 82: Replacing Batteries

    Section 9 – Battery and Battery Charge qualified dealer technician. A STEADY RED FAULT LED confirms an internal electrical fault of the Delta-Q, and also requires charger replacement and return. REPLACING BATTERIES The batteries are located under the seat. REMOVING BATTERIES Remove nuts, washers and cables, positive lead and negative lead interconnecting batteries.
  • Page 83 Section 9 – Battery and Battery Charge...

  • Page 84: Section 10 - Traction Drive System

    Service Manual Section 10 Traction Drive System TRACTION MOTOR MAINTENANCE...

  • Page 85: External Inspection

    Section 10 – Traction Drive System A good planned maintenance program will save many hours of Mark traction motor cables (if not already marked), with future down time and prevent catastrophic failure of major motor terminal identification Figure 10-1. motor components. Maintenance schedules consist of periodic routine inspections of motors, battery and wiring circuitry.

  • Page 86: Disassembly

    Section 10 – Traction Drive System 4. Clean commutator with dry, compressed air. DISASSEMBLY Remove long bolts. Remove motor head hole plug. See Figure 10-3. 2. Pull on motor head to remove armature from frame. A light tap may be required to loosen motor head from frame. Motor head and armature come out together.

  • Page 87: Armature Testing

    Section 10 – Traction Drive System ARMATURE TESTING Before the armature is reassembled into the motor, the following test should be performed. Check armature for grounded circuits by placing one test lead of a Dielectric Breakdown Tester, also referred to as a “growler”, on the commutator and other lead at armature shaft.
  • Page 88 Section 10 – Traction Drive System Hook a commercial spring scale as shown. Pull spring scale on a line directly opposite the spring force. When paper strip can be moved freely, read spring tension on scale. Brush spring tension New 64 ounces (1792 grams) Worn 40 ounces (1120 grams) Figure 10-8 Figure 10 - 9...
  • Page 89 Section 10 – Traction Drive System Figure 10-10...
  • Page 90 Section 10 – Traction Drive System...

  • Page 91: Bearing

    Section 10 – Traction Drive System Figure 10 - 11 BEARING Figure 10 - 12 After the motor has been disassembled, it is recommended that a new bearing be installed. Bearing may appear and feel ok, however, bearing may have been damaged during removal.

  • Page 92: Motor Installation

    Section 10 – Traction Drive System 10-5 Figu re 10 - 15 Pull back each brush in it’s holder, allowing the spring to rest against the side of each brush. This will hold each Figure 10 - 16 brush in place, preventing interference and damage to commutator and brushes during armature installation.

  • Page 93: Controller

    Section 10 – Traction Drive System ensure connections are correct. Figure 10-18 F1 and F2 terminals are 1/4-20 while A1 and A2 terminals Remove 16 pin controller connector (Figure 10-20). are 5/16-18. Attach cables with flat washers, lock washers and hex nuts. Torque A1 & A2 cable attaching nuts to 110 in.

  • Page 94: Contactor/Solenoid

    Section 10 – Traction Drive System (5.7 – 6.8 Nm). Reconnect battery negative cable. Insert Power key in switch and check for steady green light on controller. Perform an operational check of the vehicle’s driving abilities CONTACTOR/SOLENOID Contactor is an electro-magnetic switch that energizes when current is applied to the small control circuit terminals.

This manual is also suitable for:

Expediter ex21-24aExpediter ex21-48a

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