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Columbia ParCar P4G Service Manual

Gasoline and electric golf and industrial four wheel vehicles
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Service Manual
Gasoline and Electric
Golf and Industrial
Four Wheel Vehicles
PART NO. 99496-96
3-00

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Summary of Contents for Columbia ParCar P4G

  • Page 1 Service Manual Gasoline and Electric Golf and Industrial Four Wheel Vehicles PART NO. 99496-96 3-00...
  • Page 2 350 N. Dewey P.O. Box 30 Reedsburg, WI 53959 Phone (608) 524-8888 Toll-Free (800) 222-GOLF Fax (608) 524-8380 Web www.parcar.com E-Mail infoparcar parcar.com...

  • Page 3: Safety

    To ensure a satisfactory and lasting repair job, follow the service manual instructions carefully and use only genuine Columbia ParCar 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 ParCar parts, you use the best.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS CHAPTER # Safety General Information Steering & Suspension Brake Systems Torque Converter/Transmission System Directional Shifting Control (Gas Vehicles) & Final Drive Axles Briggs & Stratton Engines & Exhaust System Electrical System & Components...
  • Page 5 CHAPTER 1 SAFETY PAGE # Overview All Vehicles Gasoline Vehicles Electric Vehicles...
  • Page 6 Note: Notes will provides key information to assure procedures are more easily understood or implemented. It is Columbia ParCar'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.
  • Page 7 Follow all procedures exactly and observe all warnings stated in this manual. Use caution and common sense. Proper service and repair is important for safe, reliable operation of all Columbia ParCar vehicles. The service procedures recommended and described in this service manual are effective methods for performing service operations.
  • Page 8 GASOLINE-POWERED VEHICLES (CONTINUED) Danger: 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 a physician immediately. Any modifications or changes to the vehicle that affect the stability, or increases the speed beyond factory specifications, could result in severe personal injury or death.
  • Page 9 ELECTRIC-POWERED VEHICLES When working around batteries, use approved insulated tools, remove jewelry such as Danger rings, watches, chains, etc. and place an insulating material (wood, plastic, rubber, etc.) over batteries covering all connections. BATTERY - Is poisonous! Contains acid! Causes severe burns. Avoid contact with skin, eyes, or clothing.
  • Page 10 CHAPTER 2 GENERAL AND MAINTENANCE INFORMATION PAGE # Vehicle and Model Information Vehicle Identification Number (VIN) Chart Vehicle Specifications Safety Committee Pre-operation Inspections Torques and Metric Conversion Factors Torque Table Metric Conversion Chart Lifting Instructions 2-10 Hoist Lifts Floor Jacks Hydraulic Lifts Jack Stands Vehicle Storage...
  • Page 11 CHAPTER 2 GENERAL AND MAINTENANCE INFORMATION PAGE # PERIODIC MAINTENANCE 2-14 Calendar Year Reference Chart 2-14 Maintenance Schedule Checklist 2-14 Gas Vehicles 2-16 Chassis Lubrication Air Filtration Engine Oil and Lubrication Service Rear Axle Service Accelerator and Governor Controls Electric Vehicles 2-23 Batteries Chassis Lubrication...
  • Page 12 VEHICLE AND MODEL INFORMATION Model Vin Prefix Name Use Type Power System Eagle Golf Gas 4 Cycle 9 HP Briggs & Stratton Eagle Golf Battery 36/48 Volt System Eagle Golf Battery 36/48 Volt System Foursome Golf Gas 4 Cycle 9 HP Briggs & Stratton Foursome Golf Battery 36/48 Volt System...
  • Page 13 N=Utilitruck Y=Rear wheel hydraulic vehicle that you give 2400XB disc brakes the entire vehicle VIN S=Shuttle Z=Custom Carts model to Columbia ParCar U=Utilitruck customer service to X=UtilitruckXB ensure correct service Z=Ambulance parts are ordered and supplied. Note: ALWAYS, provide the complete VIN when contacting your Dealer for technical assistance or maintenance and repair parts.
  • Page 14 General Vehicle Specifications Item Specifications Vehicle GUXB EUXB Power Source Engine 9 HP 4 cycle, Single cylinder, fan air cooled, OHV Briggs & Stratton 13 HP 4 cycle, Single cylinder, fan air cooled, OHV Briggs & Stratton Motor 36 Volt, DC series wound, Reversible, NEMA Class H insulation, 3.2 HP @2800 RPM Drive...
  • Page 15 General Vehicle Specifications (Continued) Item Specifications Vehicle 2400 2400 2400XB 2400XB Power Source Engine 9 HP 4 cycle, Single cylinder, fan air cooled, OHV Briggs & Stratton 13 HP 4 cycle, Single cylinder, fan air cooled, OHV Briggs & Stratton Motor 36 Volt, DC series wound, Reversible, NEMA Class H insulation, 3.2 HP...
  • Page 16 General Vehicle Specifications (cont.) Item Specifications Vehicle C10G C10E 911G 911E Power Source Engine 9 HP 4 cycle, Single cylinder, fan air cooled, OHV Briggs & Stratton 13 HP 4 cycle, Single cylinder, fan air cooled, OHV Briggs & Stratton Motor 36 Volt, DC series wound, Reversible, NEMA Class H insulation, 3.2 HP...
  • Page 17 These basic rules of operation, combined with courtesy applications. and common sense, will help make driving your Columbia ParCar vehicle a safe and pleasant experi- 2 Six, 8-volt batteries may be used for 48-volt system. ence. The safety committee should be made up of man-...
  • Page 18 Note: Controls should operated smoothly and easily without sticking or requiring undue effort. The service manual contains maintenance procedures necessary to Your Columbia ParCar vehicle has been inspected and perform maintenance on your vehicle. Maintenance adjusted to factory specifications before delivery. Upon...
  • Page 19 Shipping Company severe personal injury, property damage or and your local Columbia ParCar Dealer. death. Consult your local Columbia ParCar Dealer for professional service. Look for body damage, jagged edges etc. that may cause personal injury.
  • Page 20 Torques and Metric Conversion Factors Individual component torques and metric equivalents are listed where the maintenance is performed throughout this manual. When a specific fastener torque is not specified, use this Torque Table as a general guide in determining the proper torque.
  • Page 21 Conversion Factors 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 micrometer 0.394 foot 0.3048 Meter 3.2808 miles...
  • Page 22 To lift the front, place the floor jack under the leaf spring Warning: DO NOT attempt to charge a battery retainer plate, and lift vehicle. Place jack stands under that is frozen or if battery case is excessively the frame at right and left sides to allow access under bulged.
  • Page 23 Returning Vehicle To Service 1. Fully charge batteries. With electrolyte full in all cells, 1. Recharge battery if required. See Battery Testing, store batteries in a cool place. If stored above 50° Chapter 8. F (27° C), check state of charge every four (4) to six (6) weeks and charge as necessary to maintain 2.
  • Page 24 Use trailers specifically designed to carry your Caution: Use caution and common sense while Columbia ParCar or Industrial vehicle that meets all towing disabled vehicle. federal, state and local requirements. Secure vehicle to the trailer following trailer manu- Use a tow chain, strap or towing device long enough facturer’s instruction.

  • Page 25: Periodic Maintenance

    Service operations A good planned maintenance program is important for will require periodic maintenance recommendations to be the safe, reliable operation of all Columbia ParCar vehi- adjusted to shorter time intervals. Examples of service cles. The service procedures recommended and...
  • Page 26 Maintenance Schedule Checklist Service/Check Procedure Daily Weekly Monthly Quarterly Semi- Annual Annual Clean Body and Seats Wash as needed Lubricate chassis Lubricate body hinges 2-17, 2-25 Lubricate front suspension Lubricate 2-17, 2-25 and steering Warning and operating Ensure labels in place and labels readable Operating Controls...
  • Page 27 2. Vehicles have nine (9) grease fittings. Two on each Your Columbia ParCar gasoline vehicle is equipped with A-arm assembly, one on each steering arm, one on the exclusive Micro-Clean air filtration system.
  • Page 28 Caution: If air cleaner primary and secondary 4. Inspect the Old Element for Uneven Patterns of elements are not tightened firmly against their Dirt gaskets, contaminants will enter the engine. This will damage the engine and void the Uneven patterns of dirt on the clean side of the old warranty.
  • Page 29 It’s better to keep using a dirty element than to replace it with the wrong replacement part. 4-CYCLE (Overhead Valve) ENGINE Use only original Columbia ParCar replacement parts OIL RECOMMENDATIONS 5 available from your Columbia ParCar Dealer. SAE VISCOSITY GRADES FUEL AND OIL RECOMMENDATIONS We recommend the use of Briggs &...
  • Page 30 MAINTENANCE Chapter 7 contains additional maintenance and repair informa- tion. Engine Oil, Lubrication Note: LONG DIPSTICK - Always screw long dipstick in Oil has four purposes. completely to check oil level. See Figure 5. •It cools, SHORT DIPSTICK - Set short dipstick into opening. •It cleans, Do not screw in to check oil level.
  • Page 31 Capacity - 1.5 quarts (1.4 L.), SAE 30 wt. Below 0°F (-17°C), use 10-30Wt. Spring Gas Axle Assembly, Tram and 2400 lb. Utility Oil Check and change intervals. Accelerator Micro Switch Check only if signs of leakage are detected, then, check oil level.
  • Page 32 As accelerator is depressed to full throttle position, throt- Bulkhead tle lever at carburetor opens completely for maximum per- Fitting formance and acceleration. As maximum governed speed is achieved, force from internal centrifical weights (within the rear axle) begin to exceed the ability of the governor spring to hold the throttle open.
  • Page 33 To remove throttle cable, use a straight edge screwdriver As the ground speed is reduced (ascending hills or to lift the cable end from the throttle lever snap fitting. See grades), the governor spring and accelerator cable, Figure 13. Loosen the bulk head fittings at both ends of pulls the governor arm back, opening the carburetor.
  • Page 34 Electric Vehicle Service Ventilation fans should be located at the highest point in the room, and must be capable of When servicing your electric Columbia ParCar vehi- changing the total volume of air in the room five cle, always observe the following: (5) times per hour.
  • Page 35 Do not operate the charger if it has received a The plug must be grounded to an appropriate dedicated receptacle that is properly installed and grounded in sharp blow, was dropped, or otherwise damaged accordance with the National Electric Code ANSI/NFPA in any way.
  • Page 36 If major repairs are ever need- putting them into service, and at least monthly on batter- ed, contact your local Columbia ParCar Dealer for assis- ies in service. Water use increases as batteries age. tance. Your Columbia ParCar Dealer has the technical...
  • Page 37 See Figure 17. Figure 19 - Remove Remaining Tabs from Console Refinishing The Columbia ParCar front body can be refinished, using standard automotive paints and flexible additives. Repair of cuts, scrapes, and gouges can be accomplished by using “flexible bumper repair” materials. Your local body and paint supply experts will have specific recom- mendations for materials and procedures.
  • Page 38 1. Set mid-body into place. Pivot mid-body forward and Handrails engage body tabs into slots in floor board. Warning: Never operate Columbia ParCar vehi- 2. Secure body restraint strap to the chassis. Do not cles without handrails in place. Operation of overtighten lock nut.
  • Page 39 Release four (4) 1/4 turn fasteners, and lift deck plate from vehicle. 2. At front of rear body, locate and remove bolts secur- ing two (2) front hinge brackets to body. See Figure 24, Front Hinge Brackets. Figure 22 - Rear Body Hinge 3.
  • Page 40 2. At front of rear body, insert front hinge brackets up through slots in floor board, and secure with four (4) bolts. 3. Recheck that rear body is positioned squarely over chassis, and tighten front and rear mounting bolts. 4. Replace seat bottom cushion. 2-29...
  • Page 41 CHAPTER 3 STEERING, SUSPENSION, & FRAME PAGE # STEERING & SUSPENSION Adjustment & Service Specifications STEERING SYSTEM Steering Wheel Removal Installation Rack & Pinion Steering Assembly Removal Installation Front Wheels & Hubs Removal Assembly & Installation Front Suspension Removal Bearing Replacement Installation Rack &...
  • Page 42 CHAPTER 3 STEERING, SUSPENSION, & FRAME PAGE # REAR SUSPENSION Shock Absorbers Inspection Removal Installation Rear Springs Removal Installation Rear Fork Removal Installation Frame 3-10 Servicing...

  • Page 43: General Information

    STEERING AND SUSPENSION Removal Adjustment and Service Specifications 1. Remove score card holder from steering wheel, by removing two (2) screws under steering wheel. Also, remove two screws securing lower steering wheel Note: Always completely inspect all vehicles steering cap to underside of steering wheel, allowing cap to and suspension components before making adjustments.
  • Page 44 3. Torque steering wheel nut to 22 to 25 ft.lbs. (3.0 to 3.5 Kgm). Rack And Pinion Steering Assembly Removal 1. Remove front body as described in Chapter 2. 2. Remove steering shaft clamp bolt securing steering Remove shaft to pinion gear of rack and pinion assembly. See Figure 2.
  • Page 45 Front Suspension Removal 1. Remove front hub as described in previous section. 2. Remove tie rod end from steering arm. 3. Remove kingpin nut at top of steering arm. See Figure 7, #21. 4. Lift A-arm bracket and A-arm, remove steering arm from kingpin.
  • Page 46 Figure 7 - Front Suspension...
  • Page 47 Bearing Replacement 5. Install kingpin on leaf spring. Do not torque at this time. Steering arm and A-arm bushings are replaceable. If bushings are worn excessively, replace bushing before 6. Slide steering arm onto kingpin, insert kingpin reassembly. through kingpin bracket. Install kingpin nut, torque to 30 ft.

  • Page 48: Steering & Suspension

    Assembly 1. Using a quality wheel bearing grease liberally lubri- cate all steering parts and inside of steering housing. 2. Insert rack gear (Figure 9 #7) into housing. Insert pinion gear (Figure 9 #11) into top of steering hous- ing, align pinion gear to rack gear. 3.
  • Page 49 Removal 4. Push tire off wheel flange into wheel well. See Figure 1. Remove hubcap and slightly loosen wheel mount nuts. 2. Lift vehicle her lifting instructions, Chapter 2. 3. Remove wheel mounting nuts and tire and wheel assembly. Installation Figure 12 - Drop Tire to Center 5.
  • Page 50 6. Install tire on wheel from valve stem side. If tire Shock Absorbers machine is unavailable, use rubber mallet and tire iron to install tire on wheel. See Figures 12 & 13. Inspection 7. Remove valve stem core and position tire so tire Check the shock absorbers for fluid leakage at the point bead is seated on bead area.
  • Page 51 9. On gas vehicles, remove engine mount plate and Removal engine plate suspension mounts. 1. With vehicle raised and the rear fork supported on jack stands (see page 6-5, Figure 8), remove two shock absorber bolts. See Figure 15. 2. Using a floor jack, raise the frame from the axle and suspension rear fork.
  • Page 52 9. Install battery into vehicle. Frame Servicing If incorrect frame alignment is suspected, contact Columbia ParCar Technical Service Department for frame specifications. Warning: For maximum safety and reliability, replace vehicle if frame is severely bent or dam- aged. Factory repair is not available and only qualified welding technicians must perform field welding or repair.

  • Page 53: Table Of Contents

    CHAPTER 4 BRAKE SYSTEMS PAGE # MECHANICAL DRUM BRAKE SYSTEM System Overview Operation Periodic Inspection Annual Maintenance Inspection Adjustments Brake Linkage Adjustment Park Brake Adjustment Brake Shoe Adjustment Brake Cables Removal & Installation Brake Assembly Service Disassembly & Assembly Tips General Disassembly Assembly...

  • Page 54: Table Of Contents

    CHAPTER 4 BRAKE SYSTEMS PAGE # Disassembly & Assembly General Brake Shoe Service Brake Drum Service Wheel Cylinder Service Service Procedures Cleaning & Inspection Hydraulic Master Cylinder 4-10 Brake Fluid Maintenance Bleeding Hydraulic System Trouble Shooting 4-11 HYDRAULIC DISC BRAKE SYSTEM 4-12 System Overview 4-12...

  • Page 55: System Overview

    MECHANICAL BRAKING SYSTEM 3. Brake shoe to drum adjustment is automatic and does not require manual adjustments. Each time brakes are applied, shoes expand outward to drum. If brake shoe System Overview travel exceeds minimum, adjuster will advance to compensate for wear. As brakes are released, The mechanical braking system consists of two wheel rear adjuster returns to normal position to repeat the drum brakes.

  • Page 56: Adjustments

    2. Remove brake drums. For brake drum removal, it may Note: Excessive brake rod and cable tension could cause be necessary to retract the brake shoes. The brake automatic adjusters in the rear brakes to become adjuster can be accessed through an inspection open- inoperative.

  • Page 57: Brake Cables

    5. If when checked on a steep incline, or on a subtle 4. Do not mix parts from left and right brake assemblies incline, the vehicle’s park brake would not hold as as they may differ. described above, refer to mechanical brake linkage for brake cable and brake rod adjustment.

  • Page 58: Trouble Shooting

    Severe reaction to pedal pressure and uneven stoping Assembly 1. Shoes and Lining 1. Before assembly, remove the automatic adjuster a. Shoes improperly adjusted - adjust. screw from the automatic adjuster nut and clean the b. Shoes distorted or incorrect; linings incorrect, parts thoroughly.

  • Page 59: Brake Systems

    HYDRAULIC BRAKING SYSTEM Operation System Overview Hydraulic drum brake systems utilize a combination of mechanical and hydraulic components. A mechanical brake pedal and linkage is utilized to actuate a master 2400 lb. Utilitruck and Tram vehicles come standard with cylinder. The master cylinder is used to create hydraulic hydraulically operated drum brakes.

  • Page 60: Periodic Maintenance Inspection

    c. Operate vehicle on level ground, applying brakes to 2. Remove Tinnerman fasteners on lug bolts holding ensure that both rear brakes apply equally. Also, brake drum. Remove brake drums. It may be neces- check that excessive force is not required to apply sary to retract brake shoes.
  • Page 61 Hand Operated Parking Brake Brake Shoe Adjustment Lift on park brake handle to monitor the amount of travel. a. To check rear brake shoe adjustment, depress brake You should normally hear the handle click or ratchet two pedal. Pedal should move approximately 1/2 to 1 inch or more times before resistance is felt and park brake is of travel before resistance is felt.

  • Page 62: General

    Disassembly & Reassembly Note: It is not recommended that the hydraulic drum Dust Cover Park Brake brake assembly be removed for repair or service. For Piston Actuating Lever Torque Dust Boot removal, refer to Chapter 7 for Rear Axle Removal. &...

  • Page 63: Brake Drum Service

    10. Once the shoes have been adjusted to create drag on Wheel Cylinder Service brake drum, rotate the brake adjuster in the opposite direction only until the brake drum will rotate freely. The wheel cylinder is 9 one piece cast assembly, and part Some sound of brake shoes contacting drum may be of the torque spider.

  • Page 64: Hydraulic Master Cylinder

    Note: If the clearance between the pistons and the bore wall exceeds .005 inch, a condition known as heel drag may exist. This causes rapid cup wear and may cause the pistons to retract very slowly when the brakes are released.
  • Page 65 2. Install a length of appropriate size plastic tubing over 3. Wheel Bearings wheel cylinder bleeder fitting, located next to wheel a. Damaged or grease contaminated - replace. cylinder line connection. See Figure 13. b. Grabbing or Pulling - replace. Severe reaction to pedal pressure and uneven stoping 1.

  • Page 66: Hydraulic Disc Brake System

    HYDRAULIC DISC BRAKE Operation Hydraulic brake systems utilize a combination of mechan- System Overview ical and hydraulic function. Mechanical brake pedal and linkage is utilized to actuate a master cylinder. The mas- All light duty gas & electric (golf or industrial/commercial) ter cylinder is used to create hydraulic fluid pressure which vehicles can be equipped with optional hydraulic rear disc operates the drum or disc brakes.
  • Page 67 c. Operate vehicle on level ground, applying brakes to 5. Install rear wheels and lug nuts snuging lightly. ensure that both rear brakes apply equally. Also, Tighten lug nuts in a criss-cross pattern, torque nuts to check that excessive force is not required to apply 65 to 70 ft.

  • Page 68: Disc Brake Service

    Brake Caliper Service Removal 1. The pistons must be removed from their bores; using hydraulic pressure to force them out is the easiest method. 2. With the pads removed from the calipers, the caliper still bolted to the vehicle, and the hydraulic lines con- nected, press brake pedal until both pistons slide out of their bores.

  • Page 69: Brake Fluid Maintenance

    Figure 19 - Remove Disk Brake Pad Figure 20 - Master Cylinder Hydraulic System Master Cylinder 4. Handling and Storing Brake Fluid Brake Fluid Maintenance a. Keep the brake fluid clean. Do not allow any for- eign material in the fluid. Caution: Do not handle hydraulic system parts with greasy hands or permit parts to come in contact b.

  • Page 70: Disc Brakes

    2. Insert the end of a length of appropriate size plastic tubing over wheel cylinder bleeder nipple, located next to wheel cylinder line connection. See Figure 3. 3. Place the other end in any clear glass jar containing about 1/2 inch of clean brake fluid. 4.

  • Page 71: Torque Converter/Transmission System

    CHAPTER 5 TORQUE CONVERTER/TRANSMISSION SYSTEM PAGE # TORQUE CONVERTOR TRANSMISSION Operation Drive Belt Removal Inspection Installation Drive Clutch Removal Disassembly Cleaning & Inspection Reassembly Installation Secondary Driven Clutch Removal Disassembly Cleaning & Inspection Assembly Installation Torque Converter/Transmission Alignment...
  • Page 72 TORQUE CONVERTOR TRANSMISSION Removal Caution: Always turn key to off position, remove Operation key, and disconnect battery negative able before continuing. Secondary Driven Primary Drive Clutch Clutch 1. Grasp drive belt firmly between primary drive and sec- ondary driven clutch, lifting briskly to create slack in belt.
  • Page 73 Note: An earlier version of clutch puller (P.N. 94452-92), can be used to aid in primary clutch removal if required. This tool will not fit exactly and the floating half pulley must be removed. Disassembly Figure 3 - Clutch Sheave Wear Reassembly Note: Do not lubricate any components of the primary drive clutch.
  • Page 74 3. Insert primary drive clutch onto crank shaft, carefully 2. Place an appropriate size hex socket onto the center aligning woodruff key to key slot in drive clutch. Push shaft. Using a mechanics three jaw puller, (jaws clutch all the way onto the crankshaft until fully turned inward) grasp the cam (Figure 4, #4) and press seated.
  • Page 75 6. Inspect shaft from fixed half pulley. Replace fixed half Torque Converter/Transmission Alignment pulley if worn, scratched, or dented. At any time the engine transaxle or torque Assembly converter/transmission is removed or repositioned, engine alignment must be checked and corrected. If Caution: Use care when assembling secondary engine realignment is not performed, vehicle could exhib- driven clutch components, avoid accidental...
  • Page 76 CHAPTER 6 TRANSMISSION SHIFT SYSTEM AND FINAL DRIVE AXLES Page # TRANSMISSION SHIFT SYSTEM Overview of Operation Console Shift Assembly Removal and Installation Console Shifter Adjustment Remove & Install Shift Cable Shift Cable Adjustment Minor Adjustment Complete Adjustment GAS VEHICLE FINAL DRIVE AXLE ASSEMBLY Service Procedures Removal of Transaxle Disassembly...
  • Page 77 TRANSMISSION SHIFT SYSTEM Overview of OperatIon The shift system is dependent on separate subsystems. Each plays a significant role in the operation of the directional transmission. a. Console shifter assembly b. Rear transaxle assembly c. Shift cable and components Console shift assembly is a side to side shift lever with an “over-center”...
  • Page 78 Console Shifter Adjustment 2. Micro switch adjustment should only be performed after the complete shift system has been adjusted. To adjust micro switches, select forward position. Locate 1. Tension springs are used to create over-center action forward micro switch and loosen mounting screws. in console shifter assembly.
  • Page 79 2. Locate the shift cable where mounted to the transaxle shift cable bracket. If more positive shifting to reverse is required, rotate two cable jam nuts to move cable housing away from transaxle. If more positive forward shift is required, rotate shift cable jam nuts to adjust cable housing towards the transaxle.
  • Page 80 GAS VEHICLE FINAL DRIVE AXLE ASSEMBLY BOOT Service Procedure for Transaxle Assembly Removal of Transaxle Caution: Always, remove key and disconnect the negative battery cable before performing any ser- vice to this vehicle. Raise the rear of vehicle and support on approved jack stands. 1.
  • Page 81 8. Remove the single bolt securing secondary transmis- sion to transaxle input shaft. With this bolt removed, the secondary transmission should slide off the input shaft. If necessary, use a pry bar to evenly pry clutch from shaft. 9. Position a floor jack under transaxle gearbox. See Figure 14.
  • Page 82 12. Remove the two (2) nuts and bolts securing transaxle to each end of rear fork. See Figure 17. 13. Have a helper steady the axle while lowering floor jack. Use floor jack to roll axle out from under vehicle. Figure 18 - Transaxle Removed Figure 15 - Remove Wheel Disassembling Transaxle...
  • Page 83 3. Wind vinyl tape on the splined portion of the input shaft to protect the seal lip. See Figure 21. Figure 24 - Governor Figure 21 - Protect Shaft 6. Pull out counter shaft, and remove counter gear. 4. Support transaxle by gear case with input shaft point- Remove spacer located under counter gear.
  • Page 84 Figure 29 - Input Shaft Assembly 11. Remove the three screws holding governor plate and weights to collar on the input shaft assembly. Use cau- Figure 26 - Removing Input Shaft tion not to damage screws which are assembled with 8.
  • Page 85 15. Remove two screws holding stopper plate and gover- nor fork to the governor shaft. Remove fork and pull the shaft out of gear case using care not to damage the seal. Use care in removing screws. Locktite was used to prevent loosening. See Figure 35. Remove bearing (6204) from behind governor fork.
  • Page 86 Figure 37 - Using a Hollow Mandrel to Press Bearings, Center Shaft Assembly Illustrated 4. Apply moly grease to bore of governor sleeve, and Figure 39 - Assembly Input Shaft slide it onto input shaft. Lift weights and position them over collar on sleeve.
  • Page 87 Guide the other, splined end, of the axle shaft into the differential assembly. Bolt the axle housing flange to the gear case with five M10x23 mm bolts. See Figure 27. Tightening Torque: 25 to 31 ft. lb. (34.3-42.2N.m) (3.45 - 4.3 Kgm.) Important: The axle housings are not identical.
  • Page 88 Vent/Filler Hole Fill Level Check Plug And Gasket 115 mm Bolt 110 mm Figure 46 - Position Spacer Bolt Drain Plug And Gasket Detent Ball, Spring, And Bolt 13. Apply grease to the bore of the counter gear and place it over the spacer. Slide the counter shaft Figure 48 - Bolt Diagram through the gear, spacer, and into the case bore.
  • Page 89 2. Secure the brake cable housing to each brake cable 10. Install accelerator cable bracket on to right axle case. bracket using an "E" clip. Tightening Torque: Important: Do not reuse "E" clips or cotter pins. Always 25 to 31 ft.lb. replace with new ones when reassembling.
  • Page 90 GAS VEHICLE FINAL DRIVE ASSEMBLY Drying TRAM AND 2400 LB. MODELS Use soft, clean, lint-free towels or rags to dry compo- nents after cleaning. Bearings should NOT be dried by General spinning with compressed air. This can damage mating surfaces due to lack of lubrication. Precautions for Disassembly After drying, parts should be coated with a light coat of The rear axle is a precision assembly, and as such any...
  • Page 91 Figure 49 - Exploded View ITEM DESCRIPTION ITEM DESCRIPTION ITEM DESCRIPTION Gear Assm., Drive Nut, Lock Housing, Axle (Rh.) Gear, Final Drive (Pinion) Seal, Oil Housing Axle (Lh.) Gear Assm., Idler Plug, Rubber Bearing, Ball Screw, Flange Hd Ring, Snap Shaft, Input Sealant (Non-Silicone Tube Assm., (Rh)
  • Page 92 Should an axle assembly require component parts Note: Tubes and axle shafts do not have to be removed replacement, it is recommended that "Original prior to housing half separation. Equipment" replacement parts be used. They may be obtained through your local service dealer, or other origi- Note: The axle shaft can remain in the tube when nal equipment manufacturer parts supplier.
  • Page 93 3. Use two pry bars and the pry notches in the carrier Note: Be sure to check gears to see how they are housing, separate the housing halves. Apply equal arranged. The recessed side of the gear should face the pressure at all three notches to separate without clutch.
  • Page 94 Figure 61 - Remove Snap Ring Figure 64 - Remove Input Shaft 8. Remove the snap ring from the socket head screw 11. Remove the input shaft from the carrier housing. with snap ring pliers. Place parts on a clean shop towel to prevent damage.
  • Page 95 Figure 67 - Remove Governor Shaft Figure 70 - Input Shaft and Components 14. Clean dirt, corrosion, etc. from the outer portion of Shown is the input shaft with governor backing plate, the governor actuator shaft, then remove the gover- governor actuating sleeve and shim removed.
  • Page 96 17. Use an arbor press and a tool of appropriate diame- For axle housing, axle & bearing and hydraulic brake ter to remove seals and bearings from carrier hous- removal and assembly, refer to page 6-32. ing. Discard old seals. New seals will be installed during reassembly of unit.
  • Page 97 22. Press output shaft and intermediate shaft bearings Note: Before installing the shifting actuator, apply light oil into housing. Bearings should seat to shoulder in to the seal lip and to the actuator shaft. housing. Use the appropriate diameter tool, apply force only to the outer race of the bearing.
  • Page 98 30. Install detent ball, spring, and set screw into housing after shift rod has been installed. Tighten set screw approximately halfway. The shift rod should move up and down into three detent positions. Move the shift rod to the "reverse" position (the third detent when sliding the rod into the housing).
  • Page 99 35. Torque the bolts in the ring gear. 37. Place a bead of gasket material around the lip of one Torque 35-45 ft. lb. housing half. Apply the material around the inside of (47 To 61 N.m.) bolt holes and around the outside of dowel pinholes. Join halves, aligning dowel pins to holes.
  • Page 100 ELECTRIC VEHICLE FINAL DRIVE AXLE Cleaning and Inspection ASSEMBLY Cleaning General Precautions for Disassembly 1. Parts should be cleaned with emulsion cleaners or petroleum based cleaners. The rear axle is a precision assembly and any repair or replacement of parts must be done with great care in a 2.
  • Page 101 Figure 90 - Exploded View Item Description Qty. Item Description Qty. Item Description Qty. Carrier Sub-Assembly Bearing - Ball Brake Assembly, L.H. Bearing Cap Snap Ring Brake Assembly, R.H. Bolt-Bearing Cap Plug - Cup Bolt - Brake (160mm Brake) Diff. Case Assembly Cover - Carrier Nut (160mm Brake) Gear - Output...
  • Page 102 Disassembly 4. Remove inner snap ring. Use caution as not to dam- age bearing surfaces. Axle Shaft, Bearing, and Oil Seal 1. Remove cotter pin, then remove drum/hub nut from end of axle shaft. Figure 94 - Axle Shaft & Bearing Assembly Removal 5.
  • Page 103 Figure 97 - Axle Bearing Removal 7. After removing left and right axle shafts (See Axle Shaft, Bearing, and Oil Seal Disassembly Section): Figure 99 - Separate Cover Plate From Housing a. Remove ten (10) cover plate screws. Note: Bearing caps are marked for identification. Letters or numbers are stamped in horizontal and vertical posi- tion.
  • Page 104 10. Using a bearing puller, remove differential bearings from each side of differential case. Figure 104 - Remove Dust Cover 13. Remove snap rings from each intermediate bore. Figure 102 - Differential Bearings Removal 11. Remove four (4) bolts and nuts from the final drive gear.
  • Page 105 19. Remove "O" rings from outer input bearing bore, and both intermediate bearing bores. Figure 107 - Intermediate Bearings Removal 16. Repeat step 3-3 for intermediate bearing on opposite Figure 110 - ‘O’ Rings Removal side. 20. Remove "O" rings at each end of intermediate shaft on bearing shoulders.
  • Page 106 27. After "O" ring installation on shaft and in housing, install intermediate shaft and gear assembly through bottom opening in housing. Note: Small end of intermediate shaft and gear assem- bly must be tilted toward bottom opening until bearing trunnion visually engages intermediate bores. 28.
  • Page 107 36. With properly sized seal driver, install shaft seals. Note: Seal to be installed to dimension shown in axle shaft, bearing, and oil seal disassembly, Figure 92, page 6-26. Seal lip should be coated uniformly with light oil or grease before inserting axle shaft. Figure 116 - Install Differential Case 33.
  • Page 108 39. Insert axle shaft assemblies into tubes. With a prop- erly sized hearing driver, tap assembly until it is seat- ed firmly against inner snap ring. Refer to Figure 92, page 6-26. Note: Rotation of shaft may be required to engage differ- ential splines during installation.
  • Page 109 Figure 126 - Remove Axle and Brake Assembly 4. Use an internal puller to remove the inner axle shaft seal. Discard the seal. Figure 129 - Drill Retaining Ring Note: Avoid contacting seals with cleaning solvent during 7. Use a chisel to split and remove the retaining ring. A cleaning operation.
  • Page 110 Assembly Figure 134 - Axle And Brake Assembly Components 2. Support the bearing assembly in a suitable press. Figure 132 - Components of One-Piece Axle Shaft One-piece axle shaft: 22/23……………Shaft, Left or Right 26……………….Seal, Inner 28……………….Bearing and Race 33……………….Bolt 34……………….Nut 35……………….Bolt 37……………….Seal, Outer 38……………….Retaining Ring...
  • Page 111 7. Assemble bearing retainer bolts and new gasket material on the axle housing. Then, install axle shaft assembly into axle housing. Care should be taken not to damage oil seal. Push axle shaft as far as possible into axle housing. Figure 140 - Install Axle And Brake Assembly Figure 137 - Place Retaining Ring On To Axle 5.

  • Page 112: Briggs & Stratton Engines

    CHAPTER 7 COLUMBIA ParCar/BRIGGS & STRATTON ENGINES PAGE # FOREWORD SPECIFICATIONS ENGINE IDENTIFICATION WARNINGS THEORY OF OPERATION FUEL AND OIL RECOMMENDATIONS MAINTENANCE Lubrication/Oil Change Oil (Crankcase) Cooling Tune-Up Procedure Overhaul Procedure CHECK UP 7-10 Compression 7-10 Ignition 7-10 Carburetion 7-10 CARBURETOR, 9 &...
  • Page 113 CHAPTER 7 COLUMBIA ParCar/BRIGGS & STRATTON ENGINES PAGE # (CONTINUED) CARBURETOR SERVICE, 9 H.P. ENGINE (CONTINUED) Disassembly (Continued) 7-13 Remove Idle Mixture Valve Remove Choke Shaft Remove Throttle Valve & Shaft Fuel System Cleaning 7-15 Clean & Inspect Carburetor & Fuel Systems...
  • Page 114 CHAPTER 7 COLUMBIA ParCar/BRIGGS & STRATTON ENGINES PAGE # (CONTINUED) FUEL PUMP 7-25 Description 7-25 Operation 7-25 Removal 7-25 Installation 7-26 FUEL FILTER SERVICE 7-26 FUEL TANK 7-26 Inspection 7-26 Removal 7-26 Installation 7-26 IGNITION SYSTEM 7-27 Check Ignition 7-27...
  • Page 115 CHAPTER 7 COLUMBIA ParCar/BRIGGS & STRATTON ENGINES PAGE # (CONTINUED) ENGINE REMOVAL AND INSTALLATION (CONTINUED) Engine Alignment 7-34 COMPRESSION 7-34 Compression Testing 7-34 Compression Testing with Leakdown Tester 7-34 Cylinder Head 7-35 Remove Rocker Cover Remove Cylinder Head Disassemble Cylinder Head, 9 H.P. Engine Disassemble Cylinder Head, 13 H.P.
  • Page 116 CHAPTER 7 COLUMBIA ParCar/BRIGGS & STRATTON ENGINES PAGE # (CONTINUED) LUBRICATION SYSTEM 7-41 Engine Oil 7-41 Oil Dipper Lubrication 7-42 Oil Dipper Inspection 7-42 OIL GARD® SYSTEM 7-42 Principles of Operation 7-42 OIL GARD® TROUBLE SHOOTING 7-43 Disassemble 7-43 Inspect...
  • Page 117 CHAPTER 7 COLUMBIA ParCar/BRIGGS & STRATTON ENGINES PAGE # (CONTINUED) CRANKSHAFT AND CAM GEARS 7-47 Removal 7-47 Remove Crankshaft 7-47 Inspect Crankshaft 7-48 Check Cam Gear 7-48 Polish Crankshaft Journals 7-48 Install Crankshaft 7-48 Install Cam Gear 7-48 Install Crankcase Cover...
  • Page 118 CHAPTER 7 COLUMBIA ParCar/BRIGGS & STRATTON ENGINES PAGE # (CONTINUED) Crankcase Cover 7-56 Installation Specification Tables 7-57 SYNCRO-BALANCE® SYSTEM 7-57 Description 7-57 Remove Rotating Counterweight 7-57 Inspect Counter Weight Shaft 7-58 Install Counterweight Shaft 7-58 EXHAUST SYSTEM 7-58 Operation 7-58...
  • Page 119 Briggs & Stratton Corporation This portion of the Columbia ParCar Service Manual includes materials reproduced from the Briggs & Stratton Service Manual Part # 272147. Contents of this manual are subject to change, and were (to our knowledge) the most recent at the time of publication.
  • Page 120 HANDY REPAIR CHECK CHART COMMON SPECIFICATIONS FOR OHV SINGLE CYLINDER ENGINES 1. Spark Plug Gap: .030” .76 mm All Models Table 1 Engine Idle RPM Torque Specifications Valve Clearance Armature Air Gap Cylinder Conn. Crankcase Intake Exhaust Flywheel Inches Inches Inches Cover or Head...
  • Page 121 HOW TO READ BRIGGS & STRATTON MODEL, TYPE AND CODE NUMBERS All Briggs & Stratton engines have a unique numerical designation system. Each engine is identified be a Model, Type and Code number. Example: Model Type Code 185430 009901 95100649 The model number identifies the engine configuration.
  • Page 122 16. DO NOT crank engine with spark plug removed. If damaged or if cap does not seal properly. engine is flooded, place throttle in "FAST'' position NOTE: Use Original Columbia ParCar/Briggs & Stratton and crank until engine starts. Service Replacement Parts when servicing your engine.
  • Page 123 THEORY OF OPERATION Briggs & Stratton Single Cylinder OHV engines are of the same basic 4-stroke cycle design used in automobiles, aircraft, trucks, and tractors. As the name indicates, there are four strokes to one complete power cycle: 1. INTAKE STROKE 2.
  • Page 124 Air cooled engines run hotter than automotive engines. Use of multi-viscosity oils (10W-30, etc.) above 40° F (4° C) will result in high oil consumption and possible engine damage. Check oil level more frequently if using these types of oils. ** SAE 30 oil, if used below 40°...
  • Page 125 TUNE-UP PROCEDURE By performing the following steps you will either be sure that the engine is functioning properly or will know what major repairs should be made. The steps are also covered in the Overhaul Procedure and will normally be performed as a part of the complete overhaul. Carbon deposits in combustion chamber should be removed every 100 to 300 hours of use (more often when run at steady loads), or whenever cylinder head is removed.
  • Page 126 OVERHAUL PROCEDURE The Overhaul Procedure, which follows, is intended to help you become accustomed to a systematic method of repairing Briggs & Stratton OHV engines. Naturally, these steps could be rearranged in different order but efficiency is obtained when the repair operations are performed in the same sequence every time. The exact procedure will vary according to the engine model being repaired.
  • Page 127 Repairs PAGE REPAIRS PROCEDURES 7-50 Resize cylinder bore to next oversize, if required 7-37 Replace valve guides - intake or exhaust 7-37 Reface valves, seats, and lap 7-27 Replace ignition armature, if required 7-15 Replace throttle shaft bushings 7-13 Repair carburetor 7-52 Replace main bearings and seals Reassembly...
  • Page 128 CHECK-UP Note: If engine runs but misses during operation, a quick check to determine if ignition is or is not at fault can be Most complaints concerning engine operation can be made by inserting the #95970-96 tester between the igni- classified as one or a combination of the following: tion cable and the spark plug.
  • Page 129 As the bowl fills, the float rises, moving the inlet needle CARBURETOR, 9 & 13 H.P. ENGINES toward the inlet seat. When the inlet needle contacts the seat, fuel flow into the bowl stops, Figure 6. Fuel remains Warning: Always turn key switch to off position, at this level until engine operation begins to draw fuel from and remove key.
  • Page 130 The fuel being pushed up the idle passage enters the cen- ter of the idle fuel jet and mixes with air from the idle air Partial Venturi Vacuum jet. This air/fuel mixture then is pushed to the primary idle Atmospheric Throttle port and out into the carburetor throat.
  • Page 131 SERVICE BRIGGS & STRATTON/ 9 H.P. Bowl CARBURETOR - (MIKUNI CARBURETOR) Washer Removal Warning: Use care when working with fuel system. Clean up any spilled fuel immediately before continuing. Never service or repair fuel system near open spark or flame. Screw 1.
  • Page 132 Remove Idle Mixture Valve Pry off idle mixture valve limiter (when so equipped) and Nozzle remove idle mixture valve, Figure 18. Figure 15 - Nozzle Removal Idle Mixture Nozzle Valve Figure 18 - Removing Limiter and Idle Mixture Valve Remove Choke Shaft Note: When removing Choke Valve or Throttle Screws, use a 1/4"...
  • Page 133 2. Replace body if any of the above conditions exist. Remove Throttle Valve and Shaft 1. Remove two (2) screws from throttle valve and 3. Use only compressed air to clear plugged opening. remove throttle valve, Figure 20. 4. Inspect idle mixture needle for bent point or a groove in tip of needle.
  • Page 134 Install Pilot Jet Install pilot jet, Figure 26. Tighten securely. Throttle Valve Pilot Fuel Inlet Stamped Numbers Figure 24 - Installing Throttle Valve, 5. Rotate throttle shaft to check for binding and correct, if needed. Install Choke Shaft and Valve Figure 26 - Installing Pilot Jet 1.
  • Page 135 Install Float Bowl Gasket Install Float Assembly Install carburetor bowl gasket in carburetor body groove, or on flange of carburetor body. See Figure 28. Make sure gasket does not twist or kink. Bowl Gasket Figure 28 - Installing Bowl Gasket, Assemble Float Needle and Float Figure 30 - Installing Float Assembly Slide fuel inlet valve assembly onto float tab, Figure 29,...
  • Page 136 Float Hinge Pin (Flat End) Post First Install Second Carburetor Install Nozzle Main Jet Hinge Pin Posts Figure 32 - Installing Float Hinge Pin Inspect Float Setting Figure 34 - Installing Carburetor Nozzle and Main Jet, 1. With carburetor body upside down, the float should be High Altitude Compensation parallel with carburetor bowl mounting surface.
  • Page 137 Carburetor Installation 1. Place carburetor manifold gasket on carburetor mounting studs. Install carburetor spacer on studs with arrow towards cylinder head See Figure 36. Note: These gaskets are not interchangeable. Always make certain the correct gaskets are used at all three locations.
  • Page 138 3. Rotate idle speed screw clockwise ONLY until adjust- 10. Insert choke cable into choke lever swivel, tighten ment screw lightly contacts throttle lever. swivel lock screw. Note: Never allow idle speed screw to hold throttle open. 11. Pull choke knob on console to verify choke operation If throttle is held open, backfire and erratic starting will and adjustment.
  • Page 139 Remove Carburetor - 13 H.P. Engine Choke Shaft 1. Loosen swivel screw securing choke cable to choke 1. Rotate choke shaft and valve to closed position, hold lever. and remove two screws securing choke valve. See Figure 44. 2. Remove two hex nuts holding carburetor intake elbow and throttle cable support bracket.
  • Page 140 Remove Fuel Inlet Seat 1. After cleaning, inspect for wear, damage, cracks, or plugged openings. 1. Use self-threading screw, Flywheel Puller, or 1/4-20 tap. 2. Replace carburetor if any of the above conditions exist. 2. Thread screw or tap into fuel inlet seat 3-4 turns and remove.
  • Page 141 Install Fuel Inlet Seat Note: If throttle valve is not correctly positioned, screw holes will not align with throttle shaft. Make sure idle stop • Using a flat tipped object approximately 5/16” inch diam- screw is loosened completely and throttle valve is careful- eter, press fuel inlet seat into carburetor body until flush ly centered before tightening screws.
  • Page 142 Note: See Cable Adjustment page 2-21 for cable adjust- Table 4 Main Jets ment procedure. Standard and High Altitude Main Jets Standard High Altitude Engine Type 13 H.P. Install Inlet Needle Valve and Float 1. Insert inlet needle valve in slot on float. 2.
  • Page 143 Carburetor Adjustment FUEL PUMP Description Caution: When adjusting carburetor, always sup- port rear of vehicle off of ground. Always support rear of vehicle on jack stands to support vehicle The fuel pump, mounted on the main frame at the right off of ground to prevent accident or injury.
  • Page 144 Fuel Pump Installation For best results, always, use original Columbia ParCar/ Briggs & Stratton parts. Refer to your Columbia ParCar parts manual for part number information. 1. Place fuel pump on main frame, recessed into mounting bracket. Install two mounting screws. See FUEL TANK Figure 55.
  • Page 145 Warning: DO NOT REMOVE SPARK PLUG WHEN CHECKING IGNITION. A fire or explosion may occur from ignition of the mixture exiting the spark plug hole. Spark Columbia ParCar/Briggs & Stratton OHV engines use Plug ® MAGNETRON ignition (a transistor [no moving parts], Figure 58 - Running Check ignition armature), and flywheel magnets.
  • Page 146 2. Use flywheel holder (CPC part #95900-96) to hold fly- Remove MAGNETRON® Armature wheel from turning, Figure 62. 1. Remove blower housing. The flywheel does not need to be removed to service 1/2” MAGNETRON® ignition except to check keyways, fly- wheel key, and oil seals.
  • Page 147 Install Flywheel 1. Install stop switch wire on armature, Figure 66. Warning: Do not use impact wrenches to install 2. Place armature on cylinder with armature pilot in boss flywheel. on cylinder, Figure 67. Note: On 9 H.P. engines, MAGNETRON® armature must Armature Pilot Goes Here be installed before installing flywheel.
  • Page 148 ® 2. Tighten both screws to 45 in. lbs.(52 kgcm/kpcm). Install MAGNETRON Armature13 H.P Engine See Figure 69. 1. Install stop switch wire on armature. See Figure 72. Spark Plug Wire Routing Stop Wire 1. Route spark plug wire through notch in heat shield Wire Clip and notch in blower housing, Figure 70.
  • Page 149 2. Install oil guard bracket and module if applicable. See Figure 76. 45 in. lbs. Thickness Gauge Oil Gard Bracket Figure 76 - Installing Oil Gard® Bracket, Typical Figure 74 - Magnet Under Armature 3. Install remaining fan housing screws. Install Fan Housing 1.
  • Page 150 ENGINE REMOVAL AND INSTALLATION Danger: Gasoline is extremely flammable and should be kept away from spark, open flame or possible source of ignition. Quickly clean up Removal any spilled fuel to prevent accidental fire and or injury. Use the following to remove 9 or 13 H P engines from all gas-powered vehicles.
  • Page 151 FRONT REAR REMOVE REMOVE Figure 80 - Engine Mount Bolts Figure 81 - Engine Mount Bolts Installation Danger: Gasoline is extremely flammable and should be kept away from spark, open flame or possible source of ignition. Quickly clean up 1. Lift engine into place on engine mount plate. Secure any spilled fuel to prevent accidental fire and or engine to mount plate with for bolts washers and injury.
  • Page 152 Engine Alignment Caution: Always turn key off, and remove key. Connect spark plug wire to engine ground before continuing. At any time the engine, transaxle, or transmission is removed or repositioned, engine alignment must be Spin flywheel counterclockwise (flywheel side) against com- checked and corrected.
  • Page 153 Caution: Injury may occur if the crankshaft is not positively locked from rotating. The air pressure a. Air flowing between cylinder and cylinder head can create a rotational force of up to 60 ft. lbs. (70 indicates that cylinder head gasket is leaking. kg/cm, kp/cm81.4 Nm) if the crankshaft is not b.
  • Page 154 2. Then remove rocker arm studs and push rod guide. Breather Valve Cover Tube Breather Disassemble Cylinder Head - 13 H.P. Engine 1. Remove two (2) hex. screws holding rocker arm shaft Screws Screws to cylinder head, Figure 88. Screws Figure 85 - Removing Valve Cover, Typical Remove Cylinder Head Remove cylinder head screws, cylinder head, push rods,...
  • Page 155 4. Slowly relieve tension on spring and retainer. Valve Guide Service Inspect Valve Guides - 9 and 13 H.P. Engines 5. Remove spring, valve and valve stem seal (intake valve only). Discard valve stem seal. 1. Measure intake and exhaust valve guides using CPC Part #95990-96, Valve Guide Plug Gauge.
  • Page 156 3. Install rocker arm studs, torquing studs to torque list- Valve ed in Table 8, page 7-40 . See Figure 93. Push Rod Guide Valve Studs Spring Retainer Figure 94 - Installing Rocker Balls and Screws, Typical Figure 93 - Installing Push Rod Guide and Studs 4.
  • Page 157 Install Rocker Arms - 9 H.P. Engines Torque Screws To 85 in. lbs. 1. Install push rods through push rod guide making sure push rods are in valve tappets, Figure 96. Push Rods Figure 98 - Installing Rocker Arm Shaft Adjust Valve Clearance - 9 and 13 H.P.
  • Page 158 7. Recheck clearance and readjust, if required. Note: Correct positioning of crankshaft is required to cor- Table 7 - Valve Seat Width rectly adjust valve clearance. Intake Exhaust Install Valve Cover Model Valve Valve Install valve cover with new gasket, Figure 100. Install four 9 &...

  • Page 159: Engine Oil

    Check Breather (Valve Cover) 1. Breather valve is an integral part of the valve cover, Table 11 - Rocker Ball Set Screw or Nut Torque and can be checked on or off the engine. In. Lbs. Model Series (Nm) 2. Blow air through breather tube. There should be no leakage.
  • Page 160 If engine is running low on oil, the Oil Gard® float switch Oil Dipper Lubrication will close and the engine will stop. Engine cannot be restarted until sufficient oil is added. Fill to FULL mark on The dipper is an integral part of the connecting rod cap dipstick.
  • Page 161 ® TROUBLESHOOTING OIL GARD System Stop Wire Engine Starts, And Dies, or Will Not Start Wire Clip 1. Check engine oil level. If low, add oil to bring to full mark on dipstick. If engine starts and continues to run, problem corrected.
  • Page 162 3. Install internal engine parts per Figure 148, page 7- Piston Piston 58. Install crankcase cover as described on page 7- Pin Lock 4. Install fan and fan housing as described on pages 7- Needle Nose Pliers Table 13 Approximate Crankcase Oil Capacity (Dry) Model Capacity...
  • Page 163 Inspect Piston Ring End Gap If piston pin bore, Figure 115, is worn above reject size, Table 17, replace piston. 1. Clean all carbon from the end of the rings, and from the cylinder bore. 2. Insert old rings one at a time one inch down into the Piston Pin Bore cylinder.
  • Page 164 4. Clean and oil crankshaft crankpin. Center 5. Pull connecting rod against crankpin and install rod Barrel Face cap with match marks aligned, Figure 120. (Plated) ID Mark Must Face Top Of Piston Expander Oil Control Rings Figure 117 - Piston Ring Installation 4.
  • Page 165 Table 16 - Connecting Rod Reject Sizes Crankpin Piston Pin Model Bearings Bearing Series 1.339” .7102” 9 H.P. Engine (34.01 mm) (18.04 mm) .8028” 1.4984” 13 H.P. Engine (20.39 mm) (38.06 mm) Dowel Pins Crankcase Table 17- Piston Pin & Piston Pin Bore Reject Size Cover Figure 121 - Removing Crankcase Cover Piston...
  • Page 166 Polish Crankshaft Journals Inspect Crankshaft Polish crankshaft with crocus 200 grit cloth until polish Table 19 shows reject sizes of various wear points of the lines are uniform over entire journal, Figure 125. Direction crankshaft. Discard crankshaft if worn smaller than size of polish lines must be as shown in Figure 125.
  • Page 167 Install Crankcase Cover Adjust Crankshaft End Play 1. Install dowel pins into engine crankcase. Align gasket If crankshaft end play is more than shown in Table 23, use on to dowel pins. thrust washers between PTO ball bearing and crankcase cover until correct end play is obtained.
  • Page 168 CYLINDERS AND BEARINGS Resizing Cylinders ALWAYS RESIZE TO EXACTLY .010" OR .020", (.25 MM, Columbia ParCar/Briggs & Stratton OHV engines use ball OR.50 MM) OVER STANDARD SIZE AS SHOWN IN bearings to support the crankshaft. TABLE 24. IF THIS IS DONE ACCURATELY, THE...
  • Page 169 The cylinder is not worn at the bottom but is round so it will Top To Be Level guide the hone to straighten cylinder bore. 7. As the bottom of the cylinder increases diameter, gradually increase strokes until hone travels full length of bore.
  • Page 170 Table 26 - Camshaft Bearing Reject Sizes Inches Engine Gauge # Millimeters 45 Degrees (mm) 9 H.P. .593” & (15.06 mm) 13 H.P. Check Ball Bearings To check a ball bearing rotate bearing slowly by hand; if any roughness is felt, bearing should be replaced. Figure 131 - Cross Hatch Remove Magneto Ball Bearing - 9 H.P.
  • Page 171 Install Magneto Ball Bearing - 9 H.P. Engines 2. Assemble Part #95910-96, Washer to Tool #95930- 96, Puller Screw and insert through large end of Tool #95940-96, Driver. Bearing Installation Tools Components Tool/Part 3. Then, assemble a second washer over puller screw Tool/Part # up against bushing.
  • Page 172 Tool # Tool # 95951-96 95950-96 4. Insert screw with driver through ball bearing and Tool # thread into support. Continue tightening screw until 95930-96 ball bearing is removed, Figure 137. Bearing Installation Tool Components Tool/Part Part # Tool/Part # 95910-96 Description Washer...
  • Page 173 1. Lubricate outside diameter of ball bearing before Bearing Removal Tool Components installing. Install shim(s) if used. Tool/Part Tool/Part # 2. Place ball bearing on Tool #95951-96, support. Description 3. Assemble Part #95910-96 Washer, to Tool #95930- Washer 95910-96 (2) 96, Puller Screw.
  • Page 174 5. Turn nut down unto Tool #95953-96, Puller Stand Off. Crankcase Cover 6. While holding puller screw from turning, turn nut until Installation ball bearing is free, Figure 141. Protect oil seal when installing crankcase cover or sump. Tool # Screw DO NOT FORCE COVER OR SUMP.
  • Page 175 9 & 13 H.P. Engines Marks (19.7) SYNCHRO-BALANCE ® SYSTEM Description The Columbia ParCar/Briggs & Stratton Engine uses a geared rotating counterweight that rotates in the opposite direction to the crankshaft counterweights, Figure 145. Figure 146 - Aligning Timing Marks 7-57...
  • Page 176 Inspect Counterweight Shaft EXHAUST SYSTEM Inspect bearings and gear teeth for wear, scoring, or dam- Operation age, Figure 147. Replace if damaged. Gear Teeth Exhaust system is used to muffle engine exhaust noise and direct engine exhaust gases out under rear of vehicle.
  • Page 177 Figure 152 - Engine Exhaust Pipe Clamps Installation of Exhaust System 1. Install engine exhaust pipe to engine using new Figure 150 - Remove Worm Gear Clamps exhaust gasket. Torque nuts evenly to 175 in. lbs. 3. Remove choke cable mounting bracket from tab at (19.6 N.m.).
  • Page 178 6. Install two worm gear clamps around muffler. Note: Position screw ends of clamps at approximately 10 O’clock position, as shown in Figure 150. 7. Lift muffler and cradle to align horizontally with engine exhaust pipe. While holding muffler cradle in place, tighten four muffler cradle mounting bolts to 18 ft.

  • Page 183: Electrical System & Components

    CHAPTER 8 ELECTRICAL SYSTEMS & COMPONENTS PAGE # GAS VEHICLE ELECTRICAL SYSTEMS & COMPONENTS Operation Micro Switches Accelerator Micro Switch Console Shifter Micro Switches Key Switch Electrical System Testing Trouble Shooting Guide Engine Kill Circuit Diode Testing Voltage Regulator Charge Circuit Test Testing Starter/Generator &...
  • Page 184 CHAPTER 8 ELECTRICAL SYSTEMS & COMPONENTS PAGE # (Continued) ELECTRIC VEHICLE ELECTRICAL SYSTEMS AND COMPONENTS 8-16 Electric Vehicle Battery 8-16 Inspection and Maintenance Charging Charge Procedure Conditions Which Affect Charging Testing Battery Testing With A Charger Specific Gravity Test Using the Hydrometer Interpretation of Hydrometer Readings Discharge Load Test Preparation for Discharge Test...
  • Page 185 CHAPTER 8 ELECTRICAL SYSTEMS & COMPONENTS PAGE # (Continued) XP Speed Control System 8-30 Solid State Speed Control Adjustment Check Speed Control Adjustment Adjust Speed Control Electrical Operation and Circuits Charging Trouble Shooting Guide, XP Speed Control System XP Speed Control Wire Diagram XP Plus Speed Control System 8-36 Operation...
  • Page 186 GAS VEHICLE ELECTRICAL Micro Switches SYSTEM & COMPONENTS The gas vehicle electrical system uses several micro switches to perform specific duties. These switches may Operation occasionally require adjustment. Micro switches are used to complete or to disconnect electrical circuits. Use the The electrical system used on gas powered vehicles, following guide for adjustment of specific switches.
  • Page 187 2. Set park brake. As accelerator is depressed (and Connect black negative lead to battery negative (B-) accelerator micro switch is released), battery voltage terminal. Select DC voltage scale adequate to read will be observed. This indicates the switch has acti- 12 DC volts.
  • Page 188 Electrical System Testing system is checked. See Gas Vehicle battery, page 8-14 for details regarding battery testing The electrical system used in Columbia ParCar gas vehi- and charging. cles is designed to be simple and reliable. All circuits of the electrical system can be tested with a digital volt/ohm meter.
  • Page 189 Vehicle Will Not Click or Spin Engine To Start (Forward or Reverse) Test Results Good Voltmeter red positive lead to starter solenoid, small termi- If less than 10 DC volts, If 10 DC volts or greater is nal with orange wire and black negative lead to starter sole- proceed to next step.
  • Page 190 Vehicle Operates In Forward Only, Not in Reverse Test Results Good Voltmeter red positive lead to reverse micro switch (on the If 10 DC volts or greater, If less than 10 DC volts, check console shifter), to the tab with the red wire. Black negative continue to next test.
  • Page 191 Reverse Alarm Operates In Forward And Reverse Test Results Good Voltmeter red positive lead to reverse micro switch (on the If 10 DC volts or greater, If less than 10 DC volts, check console shifter), to the tab with the red wire. Black negative continue to next test.
  • Page 192 Engine Kill Circuit Caution: Be sure jack stands fully engage fork or frame tubes and that stands are set squarely on a level floor surface before lowering vehicle Engine spins but will not spark. onto stands. Check that vehicle is secure and will not slip from stands before operating vehi- 1.
  • Page 193 Caution: Do not ground regulator DF terminal Voltage Regulator Removal (green wire) with the regulator wire attached. Remove generator field wire from terminal and 1. Raise the vehicle body. ground the DF terminal of generator with jumper when making output tests. Warning: ParCar with angle bag rack) To secure body upright and avoid possible personal injury...
  • Page 194 2. Reconnect the voltage regulator wires as follows: 3. Brush Holder (10) is to be removed, remove terminal nuts, washers and lockwashers (8), brush holder RED WIRE (R) to generator side of solenoid. screws and lockwashers (9). Then, remove brush GREEN WIRE (GN) to green wire from engine holder (10).
  • Page 195 Caution: Use care while removing bearing from shaft so as not to damage retainer plate. 6. Remove bearing retainer (21). Note: Do not remove pole shoes unless electrical test indicates it is necessary. 7. Remove pole shoe screws (22), pole (23), DF termi- nal hardware (24) F1 and F2 terminal hardware (251 and remove field coil (26).
  • Page 196 2. Using steel blade provided with tester, or hack saw blade, hold blade parallel with and touching armature core. See Figure 12. 3. Slowly, rotate armature one complete revolution in growler. If the armature is shorted the blade will vibrate on the armature core. Shorted armatures must be replaced.
  • Page 197 Field Coil Inspection If the insulation on the field coils appears blackened or charred, the serviceability of the coils is questionable. Burned or scorched coil insulation indicates the motor has overheated due to overloads, grounded or shorted coil windings. Check for loose pole shoes. Check all terminals. Repair or replace as needed.
  • Page 198 3. Resistance should read 4.5 to 5.5 ohms. 6. Install armature (11) into drive end cover (12) and tighten bearing retainer screws (18). 4. Connect ohmmeter to DF terminal and housing (ohms reading). 7. Slide frame (3) over armature (11) and locate pins used for aligning.
  • Page 199 Danger: Batteries contain sulfuric acid, which is Read Belt Tension highly corrosive and can cause chemical burns. Avoid contact with skin, eyes or clothing. Always wear approved eye protection when working around batteries. Antidote External - Flush with water. Internal - Drink large quantities of milk or water, fol- Figure 17 - “Kricket”...
  • Page 200 Table 1 - Charging Rates, 12 Volt Battery Slow Charge Rate Fast Charge Rate 5 Amps for 10 hours 20 Amps for 2 1/2 hours 10 Amps for 5 hours 30 Amps for 1 1/2 hours Caution: If battery case feels hot (approximately 125°...
  • Page 201 Lead sulfate formed on the plates during discharge is rel- while in a partially discharged condition. This type of ser- atively insoluble as long as the specific gravity of elec- vice requires a deep cycle battery - a battery that is trolyte is kept above 75% specific gravity.
  • Page 202 c. Be sure battery hold downs are properly Note: The specific gravity check is most accurate for tightened. A loose hold down may allow the determining battery state of charge. Charger function battery to become damaged from vibration or is totally automatic. Charger will determine proper jarring.
  • Page 203 b. Fleet cars should be rotated so that all cars are used Battery banks failing this test should be tested with equally. hydrometer and/or load tester. See Specific Gravity Test. c. Battery efficiency is affected by temperature. See Specific Gravity Test Table 4.
  • Page 204 Interpretation of Hydrometer Readings b. Discharge (Load) Test must be performed within 18 hours of charging. State of charge: Check specific gravity of each cell. Refer to Tables 6 and 7. c. Vehicle must not be used, even for short runs, prior to Table 6 Discharge (Load) Test.
  • Page 205 Note: Even if individual battery voltages are satisfactory, Caution: Batteries in low state of charge (low but the discharge time fails to meet minimums in Table 8, specific gravity readings) will freeze at higher the entire battery bank should be replaced. temperatures than those fully charged.
  • Page 206 Figure 20 - Key switch Test (Electric Vehicles) Solenoid Motor Resistor Impedes current flow, which reduces voltage to circuit. This solenoid is an electro-magnetic switch which ener- Two types of resistors will be found on speed control gizes when current is applied to the small control circuit systems.
  • Page 207 Testing Pot Switch Test Testing can be performed on or off of vehicle. To deter- 1. Using a digital volt/ohm meter (set to test continuity) mine if speed switch is functioning correctly, follow pre- probe to the terminals at ends of black and white cisely testing instructions in the order as they appear.
  • Page 208 Removal 1. Remove red and black wires from micro switch mounted to speed switch. 2. Remove white and black leads from speed control White module #2 and # 3 tab terminals. 3. Remove wire ties securing speed switch lead wires to frame.
  • Page 209 3. With speed switch lever released, rotate pot switch Caution: All years and models of vehicles will (using a straight screwdriver) until correct reading of not be the same, regarding the clevis pin posi- 0 to 50 ohms is observer. tion in speed switch arm.
  • Page 210 2. Internal and external spline drives (between motor and final drive axle) must be periodically lubricated with a quality "Anti-seize" compound. 3. Check for any sign of oil leaks from final drive axle, which might cause oil to enter traction motor. 4.
  • Page 211 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 on the commutator and the other lead at the armature shaft. If the test light comes on, the armature is grounded.
  • Page 212 Do not substitute brushes. The brushes are matched to the motor type and application to provide the best ser- vice. Substituting brushes of the wrong grade can cause commutator damage or excessive brush wear. After the installation of new brushes, the motor should be operat- ed at 12 volt, no load and brushes seated to the commu- tator with a dressing stone.
  • Page 213 Assemble field coil terminals as shown in Figure 30. Table 13 Motor terminals should be torqued to 140 in./lbs. (15.5 Motor # Spring Tension N.m.). Pole shoe screws should be torqued to 250 - 300 in./lbs. (28 to 33.5 N.m.). XP Motor 65 Oz.
  • Page 214 Place motor into vehicle and onto input shaft. Rotate to align bolt holes in motor, to axle as shown in Figure 32. Install three (3) bolts securing motor to rear axle/differen- tial housing, while carefully supporting motor to prevent it from falling.
  • Page 215 XP Speed Control System (Soft Start System) b. Remove cotter pin and clevis pin. Rotate clevis to shorten or lengthen accelerator rod as required. This system uses solenoids and resistors to control cur- c. Replace pins. See Figure 34. rent flow to traction motor and vehicle direction. They are two basic circuits involved.
  • Page 216 Second Speed Reverse Key Switch position………………… Forward Key Switch position………………… Reverse Speed Switch Arm position…………Second speed Speed Switch Arm position…………Same as forward speeds Solenoid C1…………………….…… Energized; circuit connec- Solenoid C1………………………..Same as forward speeds tion between large bottom Solenoid C2…………………….…… Same as forward speeds terminals Solenoid F……………………………...
  • Page 217 Trouble Shooting Guide - XP 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. Vehicle Does Not Operate, Forward or Reverse. Test Passed Failed...
  • Page 218 Vehicle Does Not Operate In Reverse, Operates Correctly In Forward Test Passed Failed 1. Key switch in forward. Voltmeter positive red lead to green wire 36 volts = Good Less than 36 volts, check key at forward solenoid, Voltmeter negative black lead to battery neg- switch and wire harness.
  • Page 219 No Third And Fourth Speed, Operates Correctly In First And Second Test Passed Failed Key switch in forward, depress accelerator pedal through third speed 36 volts = Less than 36 volts, replace position. Voltmeter positive red lead to brown wire at C-2 solenoid, replace C-2 speed control module.
  • Page 220 XP Speed Control Wire Diagram Solenoids 8-35...
  • Page 221 XP Plus System (Curtis System) Forward Operation Key switch position forward.....accelerator pedal depressed Operation Solenoid F…………………………… Energized connection between large top termi- The XP Plus speed control system offers infinitely variable nals; large bottom terminals speed control, in forward and in reverse. This is a highly open efficient speed control system in that the pulse modulating Solenoid R……………………………Not...
  • Page 222 Trouble 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. Vehicle Does Not Operate, Forward or Reverse. Test Passed Failed...
  • Page 223 Key switch in forward, depress accelerator pedal. Voltmeter positive As accelerator is Refer to speed switch testing red lead to controller B+ terminal, Voltmeter negative black lead to depressed, below before continuing. If controller M- terminal. battery voltage speed switch testing concludes should rise to speed switch is good, then within 1 to 2 volts...
  • Page 224 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 Test Passed Failed Voltmeter positive red lead to battery B+ terminal, Voltmeter nega-...
  • Page 225 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 Test Passed Failed Voltmeter positive red lead to battery B+ terminal, Voltmeter nega-...
  • Page 226 XP Plus Speed Control Wire Diagram 8-41...
  • Page 227 Note: Always follow trouble shooting guide in exact order The Columbia ParCar Power Master System, is a unique as listed below. Performing tests out of sequence will and patented system. Cables from the armature circuit of cause inaccurate results and lost time in diagnosing the traction motor are connected to a sensor module.
  • Page 228 Note: Whenever testing the Power Master System func- tion or operation, refer to the "Operation" section above 3. Check 15 AMP fuse. If fuse is blown: to verify correct system function. These vehicles use two Check vehicle wiring for shorts or chafing and separate electrical systems.
  • Page 229 7. Connect voltmeter red positive lead to S-1 terminal Turn key switch to forward and depress accelerator and negative lead to S-2 terminal at traction motor. pedal. If operating voltage (7 to 24 DC volts) is Turn key switch to forward and depress accelerator observed, replace wire harness leads connecting pedal.
  • Page 230 Key switch in reverse, depress accelerator pedal completely. No voltage = Full battery voltage, diodes Voltmeter positive red lead to red wire at forward solenoid (terminal Good between forward & reverse ‘B’), Voltmeter negative black lead to gray wire at forward solenoid solenoids defective.
  • Page 231 Vehicle Does Not Operate In Forward, Operates Correctly In Reverse. Test Passed Failed Voltmeter positive red lead to battery B+ terminal, Voltmeter negative Full battery Less than full battery voltage, black lead to battery B- terminal voltage = Good charge and or replace batteries. 1.
  • Page 232 Key switch in forward, depress accelerator pedal completely. Within 1 to 2 volts Less than full battery voltage, Voltmeter positive red lead to controller B+ terminal, Voltmeter nega- of full battery volt- check connections from tive black lead to #2 terminal forward solenoid. age = Good controller M-, to sensor module, to reverse and forward...
  • Page 233 Key switch in reverse, depress accelerator pedal. Voltmeter positive Full battery Less than full battery voltage, red lead to white wire at #1 tab terminal of speed control module, voltage = Good diodes between forward & Voltmeter negative black lead to controller B- terminal. reverse solenoids.
  • Page 234 Power Master System Wiring Diagram, Version A 8-49...
  • Page 235 Power Master System Wiring Diagram, Version B Note: Each solenoid uses one diode between small terminals. Refer to this illustration for proper orientation. 8-50...
  • Page 236 Power Master System Wiring Diagram, Version C 8-51...

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