Columbia Journeyman Series Maintenance Manual
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Columbia Journeyman Series Maintenance Manual

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Summary of Contents for Columbia Journeyman Series

  • Page 1 Maintenance Manual...
  • Page 2 Company and their technicians. The Manual is only for the maintenance and repair of electric vehicles of Journeyman series. Columbia reserves the rights to revise the specifications and design from time to time and the electric vehicles and other products. are subject to improvement that may influence the maintenance procedure with no notice, nor obligation to alternate devices sold previously.

  • Page 3: Table Of Contents

    Chapter 1 Overview Safety Precautions ..........................1-1 Preparation for Emergency ......................1-1 Safe Use of Lubricating Oil......................1-1 Safe Use of Battery ........................1-1 Protection of Vehicle Safety ......................1-2 Electrical Safety During Maintenance..................... 1-2 Use the Designated Lifting Jack ..................... 1-5 Use Appropriate Tools...........................
  • Page 4 Removal of Canopy Rods........................3-1 Remove............................3-1 Install.............................. 3-2 Removal of the Pillar ..........................3-2 Remove............................3-2 Install.............................. 3-3 Chapter 4 Body Removal of the Front Bumper ....................... 4-1 Remove............................4-1 Removal of the Rear Tray ........................ 4-1 Remove............................4-1 Removal of the Rear Bumper ......................
  • Page 5 Inspection............................. 6-11 Install............................6-11 Chapter 7 Brake System Brake System ............................7-1 Brake Pedal............................7-2 Accelerator pedal ..........................7-3 Chapter 8 Steering System Steering System ............................ 8-1 Removal of the Steering System ....................8-2 Removal of the Steering Gear ......................8-3 Disassembly of the Steering Gear ....................
  • Page 6 High mount stop lamp disassembly....................9-16 High mount stop lamp installation ....................9-16 Wiper removal ..........................9-16 Inner mirror removal ........................9-17 ......................9-17 Inner mirror installation Chapter 10 Troubleshooting Troubleshooting Instructions Part 1..................... 10-1 Check procedures ........................10-3 Index for check procedures ......................
  • Page 7 Battery charging ........................... 11-6 Deep discharge ..........................11-7 Premature excessive discharge ....................11-7 AC power supply line........................11-7 Alternating use of vehicles ......................11-7 Electric vehicle and charger numbering ..................11-8 Battery troubleshooting diagram ....................11-9 Inspection and test of the battery ....................11-10 Inspection and test of the battery charger ..................

  • Page 9: Safety Precautions

    Overview Chapter 1 Safety Precautions WARNING During the maintenance of these vehicles, the following safety precautions can be taken to prevent serious accidents. Preparation for an Emergency To prevent a potential injury or fire hazard, the following simple articles should be prepared. For example: •...

  • Page 10: Electrical Safety During Maintenance

    Overview Chapter 1 battery should be placed in an area with good ventilation while charging. The electrolyte of the battery contains sulfuric acid, which is toxic and highly corrosive and should be prevented from being spilled onto the skins, eyes and clothes.
  • Page 11 Overview Chapter 1 • Exterior: Flush the area where acid is spilled with water, and visit the doctor immediately. • Oral medication: Drink a large quantity of milk or water before taking milk of magnesia or vegetable oil. Visit the doctor immediately. •...
  • Page 12 Overview Chapter 1 • Moveable elements! It is strictly prohibited to maintain the electric vehicle while it is in operation. • Hot! It is strictly prohibited to maintain a hot motor. Any violation of this warning may result in serious burns.

  • Page 13: Use The Designated Lifting Jack

    Overview Chapter 1 • To avoid unintentional start-up of the electric vehicle,please assure that the E-Brake switch at the middle position(Normal). • After disconnection of the battery, please wait for 90 seconds to allow for the discharge of the capacitor in the controller.

  • Page 14: Use Appropriate Tools

    Overview Chapter 1 Use Appropriate Tools To prevent the components and the vehicle from damage, appropriate tools must be used. Special Tools The use of appropriate special tools is necessary for the improvement of vehicles, accurate adjustment and assembly. The use of appropriate special tools can prevent damage resulting from the use of inappropriate tools.

  • Page 15: Tightening Torque

    We recommend that you use original parts for all Original replaceable parts. grease recommended by Columbia during the assembly, inspection and repair. Washer, Grease Fitting and O-ring During the inspection and repair of vehicles, all the washers, grease fittings and O-rings removed should be cleaned up before being mounted.

  • Page 16: Chapter 2 Regular Inspection And Adjustment

    Regular Inspection and Adjustment Chapter 2 Regular Maintenance Normal maintenance is of paramount importance to the optimal performance and safe operation of vehicles. B WARNING Unless otherwise required, the master switch must be turned off and the parking brake must be applied during the maintenance.
  • Page 17 Regular Inspection and Adjustment Chapter 2 Clean/Lubricate the pedal control area Semian Inspect all the insulated nual wires for rupture or inspection dirtiness Inspect the shock damper for oil leakage and damage of spring Annual Conduct discharging test inspection Use terminal protective agent Inspect the brake shoes for tightness and the rear...

  • Page 18: Periodic Lubrication Plan

    Regular Inspection and Adjustment Chapter 2 Periodic Lubrication Plan Periodic lubrication plan Lubricated Normal intervals Maintenance Recommend lubricating oil points Brake pedal shaft 3# Lithium based grease The user or trained Accelerator pivot bar foot 3# Lithium based grease technician applies the lubricating oil once a Charger receptacle NYE760G...

  • Page 19: Braking System

    Regular Inspection and Adjustment Chapter 2 Braking System Main Brake Inspection 1. Remove: · Anti-slip pedal · Protective cover plate Care should be taken to avoid scraping the body. 2. Inspect： · Brake master cylinder ① · Brake Oil Pipeline ② ·...
  • Page 20 Regular Inspection and Adjustment Chapter 2 3. Measure: · Free play of the brake pedal Push against the pedal by hand (slightly) and measure the distance it travels before the pressure is lost. Defects are to be replaced.

  • Page 21: Inspection Of Brake Drum And Brake Shoe

    Regular Inspection and Adjustment Chapter 2 Inspection of Brake Drum and Brake Shoe 1. Turn the key switch to the "OFF" position and take out the key. 2. Wedge the blocks onto the front lower part of the front tires. Lift the rear body with the lifting jack. 3.
  • Page 22 Regular Inspection and Adjustment Chapter 2 6. Measure In case the inside diameter of the drum does not meet the specification, it will be replaced with a new one. Standard inside diameter: 180mm（7.2 in） Maximum wearing value of the inside diameter: 1.5mm（0.06 in）...
  • Page 23 Regular Inspection and Adjustment Chapter 2 9. Install · Brake drum · Rear wheel WARNING: Verify that there is no oil or water on the surface of the brake drum and shoe block. 10. Install: Wheel nuts Tightening torque to 90N·m (66.4ft·1b) NOTICE: First, screw on the wheel nuts by hand, and then...

  • Page 24: Inspection Of The Accelerator Pedal

    Regular Inspection and Adjustment Chapter 2 Inspection of the Accelerator Pedal 1. Inspect： Operating condition of the pedal In case of unsmooth operation, the pivot should be lubricated. 2. Inspect： Lateral free travel of the pedal 4mm (0.158 in) Step on the pedal and replace the pivot in case the free play is too loose.

  • Page 25: Inspection Of The Steering Linkage

    Regular Inspection and Adjustment Chapter 2 50N·m (36.9ft·1b) And tighten: Bolts (of universal joint） Upper fixing bolt Lower fixing bolt Tightening torque to 22N·m (16.2ft·1b) 3．Re-inspect: · Steering clearance Inspection of the Steering Linkage Removal of Tie Rod Ball Joint 2.

  • Page 26: Inspection Of Stub Axle

    Regular Inspection and Adjustment Chapter 2 Inspection of Stub Axle · Free gap of kingpin bolt, spacer and bushing a. Assure that the E-brake switch is at the middle possition(Normal). b. Jack up the front wheels of vehicle c. Move the wheels lightly In case the free clearance is too large, the bushing is to be replaced or the bearing clearance is to be adjusted.

  • Page 27: Inspection Of Tires And Wheel Rim

    Regular Inspection and Adjustment Chapter 2 Procedures for the Adjustment of Toe-in: Assure that the E-brake switch is at · the middle possition(Normal). Loosen the locknut(1) on the ends of the tie rod Turn the steering tie rod to adjust the toe-in increase→...

  • Page 28: Inspection Of The Front Wheel Bearing

    Regular Inspection and Adjustment Chapter 2 · Wheel tread thickness In case of non-compliance with the standard, replacement is to be made Maximum wearing value of wheel tread thickness （front and rear tires) 4.0mm(0.16in) Inspection of the Front Wheel Bearing 1.

  • Page 29: Inspection Of The Shock Damper

    Regular Inspection and Adjustment Chapter 2 the operation, the quality of fit between half shaft and bearing or bearing sleeve may deteriorate. In this case, we usually recommend the replacement of a new rear axle half shaft assembly. Inspection of the Shock Damper 1.

  • Page 30: Inspection Of The Seat Belt

    Regular Inspection and Adjustment Chapter 2 Inspection of the Seat Belt Binding Force of the Seat Belt Pull down the seat belt swiftly and the retractor should respond quickly to seize the belt. The belt, when loosened, should be retracted back into the retractor.

  • Page 31: Chapter 3 Canopy

    Canopy Chapter 3 Removal of the Canopy Remove: 1． Disconnect high－mounted center light wire 2． Fixing bolts of the canopy 3． Canopy Install: Canopy In the reverse order of the removal procedures Tightening torque： 9N·m (6.6ft·1b) Removal of Canopy Rods Remove: 1．...

  • Page 32: Install

    Canopy Chapter 3 Install: Connect the front canopy rod and rear canopy rod, and tighten the connecting slip bolt ③ In the reverse order of the removal procedures. Tightening torque for ①, ②, ⑤ ： 22N·m (16.2 ft·1b) Removal of the Pillar Remove: 1．...

  • Page 33: Install

    Canopy Chapter 3 Install: Pillar In the reverse order of the removal procedures ① Tightening torque： 22N·m (16.2 ft·1b) Tightening torque for ②, ④, ⑤： 22N·m (16.2 ft·1b) ③ Tightening torque： 30N·m (22.1 ft·1b)

  • Page 34: Removal Of The Front Bumper

    Body Chapter 4 1. Removal of the Front Bumper Remove: · Bolt · Front bumper 2. Removal of the Rear Tray Remove: · Rear box cover · Rubber nail · Screw · Rear tray · Clamping nut 3. Removal of the Rear Bumper Remove: ·...

  • Page 35: Removal Of The Seat Cushion

    Body Chapter 4 Install: · Rear bumper · Rear bumper bracket Tightening torque： 63N·m (46.5 ft·1b) Install: · Clamping nut · Rear tray · Rear box cover Removal of the Seat Cushion Remove 1. Removal of the seat cushion: · Handrail fixing bolt ·...
  • Page 36 Body Chapter 4 · Rear seat backrest bracket ④ · Backrest ⑤ Install: · Front seat backrest · Tightening the torque of bolt: 22N·m (16.2 ft·1b) · Rear seat backrest （2+2 series） · Tightening the torque of bolt: 22N·m (16.2 ft ·1b) ·...

  • Page 37: Removal Of Front Cover

    Body Chapter 4 Removal of Front Cover Remove 1. Remove: · Front canopy rod NOTICE: Refer to "Removal of Canopy Rod" on page 3-1. · Instrument panel · Plastic nail on the upper dashboard · Fixing nuts on the lower dashboard Tightening torque：...

  • Page 38: Removal Of The Dashboard

    Body Chapter 4 Removal of the Dashboard Remove 1．Remove: · Steering wheel cover ① · Steering wheel nut ② · Steering wheel ③ NOTICE: To remove the scorecard clip, first remove the screws behind the steering wheel cover. Remove: · Combination switch connection sheath ·...

  • Page 39: Install

    Body Chapter 4 · Edging fender · Anti-slip pedal Install: In the reverse order of the removal procedures Tightening the torque of steering wheel nuts： 50N·m (36.9ft·1b) Removal of the Rear Cover Remove: 1. Remove: · Seat cushion · Seat backrest ·...

  • Page 40: Install

    Body Chapter 4 4. Remove: · Fixing bolts of lower hinge Tightening torque: 7N·m (5.2 ft·1b) · Hinge · Rear cover bolt Tightening torque: 9N·m (6.6 ft·1b) 5. Remove · Rubber nail of rear cover plate · Rear cover plate ·...

  • Page 41: Rear Cover

    Body Chapter 4 Rear cover 1. Rear cover 2. Rear cover plate 3. Rear box cover 4. Tray 5. Left rear light 6. Right rear light 7. On-board charging plug box 8. Left ventilating window 9. Right ventilating window 10. Lower hinge 11.

  • Page 42: Chapter 5 Front Axle

    Front Axle Chapter 5 Front axle 1. Upper swing arm 2. Split pin 3. Front shock absorber 4. Spindle 5. Lower swing arm 6. Brake disc 7. Oil seal 8. Cone bearing 9. Lower lug shaft 10. Hub connected plate 11.

  • Page 43: Removal Of The Front Axle

    Front Axle Chapter 5 Removal of the Front Axle Remove 1. Park the vehicle on level ground. 2.Assure that the E-Brake switch is in the middle possition(Normal). 3. Loosen: (front wheel) nuts 4. Lift up the front wheel with lifting jack. Refer to Chapter 1 "Uses of Lifting Jack".
  • Page 44 Front Axle Chapter 5 8. Remove: · Dust cover 9. Remove: · Split pin · Slotted nut 10. Remove: · Brake tongs bolt Tightening torque 23N·m (17.0 ft·1b) · Brake tongs 11. Remove: · Hub connected plate (of front wheel) Knock at the connected plate with a soft hammer.
  • Page 45 Front Axle Chapter 5 12. Remove: · Brake disc bolt Tightening torque 23N·m (17.0 ft·1b) · Brake disc Standard thickness of brake disc 4 mm (0.16 in) Maximum wearing thickness 1 mm (0.04 in) 13. Remove: · Bolt Tightening torque 23N·m (17.0 ft·1b) ·...
  • Page 46 Front Axle Chapter 5 NOTICE: The inside space and bush should be replaced together. 15．Remove: · Removal of Drag Link Ball Joint Please refer to Chapter 2 "Removal of Drag Link Ball Joint". · Split pin · Pivot slotted nut ·...

  • Page 47: Inspect

    Front Axle Chapter 5 17. Remove: · Front shock absorber bolt Tightening torque 60N·m (44.2 ft·1b) · Front shock absorber · Swing arm bolt Tightening torque 60N·m (44.2 ft·1b) · Upper and lower swing arms · Dust cover · Inside spacer ·...

  • Page 48: Install

    Front Axle Chapter 5 · Remove the oil seal and bearing with the special bearing puller. · Install new oil seal cover and bearing in the installation procedures mentioned above. NOTICE: Use a hold-down clamp that is consistent with the diameter of bearing and inside loop of oil seal cover.

  • Page 49: Driving Axle

    Driving Axle Chapter 6 Driving axle 1.Rear axle assembly 2.Gear box assembly 3.Rear Axle assembly 12.25:1 4.Sleeve, Shaft (Passenger) 5.Sleeve, Shaft (Driver) 6.Backing Plate Brake (Driver) 7.Backing Plate Brake (Passenger) 8.Brake Drum AC NKL 9.Hex Head Screw M10*1.25*35 10.Hex Head Screw M8*1.25*25 11.Serated Lock Nut M8 12.Brake Shoe (kit) 13.Brake cable clip...

  • Page 50: Removal Of The Driving Axle

    Driving Axle Chapter 6 Removal of the Driving Axle 1. Park the vehicle on level ground. 2. Lift the rear body with the lifting jack before putting a suitable bracket under the frame. Refer to Chapter 1 "Use of Designated Lifting Jack".
  • Page 51 Driving Axle Chapter 6 8. Remove: · Lower fixing nut of rear shock absorber ① Tightening torque 63N·m (46.5ft·1b) · rear shock absorber · Rear axle and rear swing arm fixing nut ② Tightening torque 63N·m (46.5ft·1b) · U-bolt · Driving axle 9.
  • Page 52 Driving Axle Chapter 6 11. Remove · Clipping spring · Locating dowel ① · Upper and lower brake retracting spring · Brake shoe Turn the locating dowel with spring or pincer pliers to separate the clipping spring and locating dowel of brake shoe. 12.

  • Page 53: Inspect And Test

    Driving Axle Chapter 6 Inspect and test 1. Measure: · Inside diameter of brake drum · Thickness of brake shoe Refer to Chapter 2. In case of non-compliance with the specification, replacement is to be made. 2. Inspect · Bottom plate of brake shoe plate ·...

  • Page 54: Install

    Driving Axle Chapter 6 Install In the reverse order of the “removal” procedures Note the following. 1. Lubricate： · External surface of the bearing Basic grease 2. Install: · Brake base plate · Half axle assembly of rear axle · Bolt ·...
  • Page 55 Driving Axle Chapter 6 Procedures for the installation of brake shoe: · Apply the high temperature grease over the two ends of the metal support of the brake shoe. WARNING In handling the brake shoe, ensure that the hands are clean and the shoe plate surface is not tainted with grease.

  • Page 56: Gearbox

    Driving Axle Chapter 6 Gearbox 01.Cover Case Assy 02.Gear Case 03.Carrier Gear Assy 04.Gear_15T 05.Gear_42T 06.Gear_16T 07.Ball Bearing-NO.6207 08.Ball Bearing-NO.6303 09.Ball Bearing-NO.6203 10.Ball Bearing-NO.6205 11.Shim-Ø 61XØ 69X1.5t 12.Shim-Ø 36XØ 44X1.5t 13. Shim- Ø 32X Ø 40X1.0t 14.Shim- Ø 45X Ø 51X1.5t 15.Washer-Ø...

  • Page 57: Removal Of The Differential Gear

    Driving Axle Chapter 6 Removal of the Differential Gear 1．Remove: Drain Screw & Washer 2．Remove: 2．Remove: Bolt & Nut x 10set ．Remove: 3．Remove: The gearbox Cover ．Remove: 4．Remove: Carrier Gear Assy...
  • Page 58 Driving Axle Chapter 6 5．Disassemble: Shim ① Bearing② 6．Remove: Seal ○ Shim ○ Shim ○ Bearing ○ 7．Remove: · Clip spring (from countershaft gear） · Bearing ⑥ · Gear bush ⑦ · Countershaft ⑧ · Countershaft gear ⑨ 6-10...

  • Page 59: Inspection

    Driving Axle Chapter 6 8．Remove: Location Pin ○ Inspection 1. Inspect: · carrier gear ① · Differential gear assembly ① In case of damage or abrasion, replacement is to be made · Bearing In case of erosion damage, replacement is to be made Install: In the reverse order of the "removal"...

  • Page 60: Chapter 7 Brake System

    Brake System Brake System Chapter 7 Chapter 7 Brake System 1. Brake pedal 3. Brake caliper 4. Rear brake 2. Oil hose 5. Front brake disc 6. Brake master cylinder 7. Brake drum 8. Iron oil tube 9. Brake pedal base 10.
  • Page 61 Brake System Chapter 7 Brake Pedal 1. Measure: · Free play of brake pedal; 13mm (0.512 in） In case of non-compliance with the specification, the brake master cylinder is to be replaced. 2. Remove · Anti-slip pedal · Protective cover plate Refer to relevant content in Chapter 2.

  • Page 62: Brake System

    Brake System Chapter 7 Accelerator pedal 1. Accelerator pedal 2. Accelerator 3. Accelerator bracket 4. Pivot 5. Split pin 6. Pin axle 7. Washer 8. Split pin 9.Flat washer 10.Lock washer 11.Throttle assy micro switch 12.Screw 13.Hall effect sensor Note: Take off 4 screws of the cover, you can see the "Hall effet sensor“ in it.

  • Page 63: Chapter 8 Steering System

    Steering System Chapter 8 Steering system (SE) 1、steering wheel 2、cover of steering cover 3、nut of steering wheel 4、bearing 5、inner snap ring 6、steering shaft 7、outer snap ring 8、protective sleeve of steering shaft 9、turn signal stalk 10、protective sleeve for wire harness 11、block of steering column 12、bolt 13、bolt 14、nut...
  • Page 64 Steering System Chapter 8 Steering system (SS / LE) 、nut of steering wheel 1、steering wheel 2、screw M5 * 1 6 4、bearing 5、inner snap ring 6、steering shaft 7、outer snap ring 8、protective sleeve of steering shaft 9、turn signal stalk 10、protective sleeve for wire harness 11、block of steering column 、...

  • Page 65: Removal Of The Steering System

    Steering System Chapter 8 Removal of the Steering System 1. Park the vehicle on level ground. ① 2. Assure that the E-Brake switch is in the middle ② possition(Normal). 3. Put a suitable bracket under the frame and lift up the front wheels with lifting jack. ④...

  • Page 66: Removal Of The Steering Gear

    Steering System Chapter 8 Tightening torque 50N·m (44.6 ft·1b) ③ · Y o ke bolt of upper steering shaft end.(See chapter 8A for details.) ③ Tightening torque 25N·m (18.4 ft·1b) · Steering column assembly 7. Disassemble: · Outer clasp ⑤ ·...

  • Page 67: Disassembly Of The Steering Gear

    Steering System Chapter 8 ② · Fixing bolts on the steering gear ② Tightening torque 45N·m (33.2 ft·1b) · Steering gear Disassembly of the Steering Gear 1. Disassemble: · Drag link ball joint of the steering gear · Secure the drawbar of the steering gear with one spanner, and loosen the locknut with another spanner.
  • Page 68 Steering System Chapter 8 EMPHASES： Observe whether there is a skewed slot on one side of the rack of steering gear. This skewed slot is designed to prevent the drawbar of steering gear from loosening. To re-install it, the thrust washer should be fixed in the skewed slot.
  • Page 69 Steering System Chapter 8 6. Disassemble: · Rack of steering gear ① 7. Inspect: · Steering gear bush · Deep groove ball bearing NOTICE: We do not recommend the replacement of worn parts in the steering gear individually. To ensure sound operating performance, we usually recommend the replacement of a new steering gear assembly.

  • Page 70: Install

    Steering System Chapter 8 · Whether the ball joint has the following symptom: Unsmooth operation ① Over-loose free gap ② Bending or deformation ③ Damage of dust boot ④ NOTICE: In case of any of the above condition, replace with a new ball joint. Install: Note the following: 1.

  • Page 71: Electrical Power Steering System

    Electrical Power Steering System Chapter 8A Electrical Power Steering System(LE/SS COUPE /SS SALOON) 1.Motor,EPS 2.Compound steering joint (UPPER) 3.Bolt,Hex-Head M8*30 4.Lock washer 8mm 5.Flat washer 8mm 6.Bolt,Hex-Head Flange M8*20 7.Holder,EPS 8.Compound steering joint (LOWER) 9.ECU,EPS 10.Bolt,hex-head flange M10*60*1.25 11.Wire harness,EPS 12.Screw ,hex-head M6*12 13.Flat washer 10mm 14.Self-locking nut M10*1.25...

  • Page 72: Removal Of Ecu (Electrical Control Unit)

    Electrical Power Steering System Chapter 8A Removal of ECU (Electrical Control Unit) ① 1. Loosen the cable ties ① ① ② 2. Remove the assorted screws ② ② 3. Remove Motor Torque Sensor wire to ECU end plug ③ ③ ④...

  • Page 73: Removal Of Eps Assy From Frame Body

    Electrical Power Steering System Chapter 8A Removal of EPS Assy From Frame Body ① ① 1. With 13mm open end wrench remove yoke bolt 1. With 13mm open end wrench remove yoke bolt of upper of upper steering shaft end. steering shaft end.

  • Page 74: Disaseembly Of Eps Assy

    Electrical Power Steering System Chapter 8A Disaseembly of EPS Assy 1. Loosen the yoke bolt ① ① and then remove the Compound steering j o int (UPPER) . ① ② 2. Loosen the 3 flange bolts and then remove the EPS Holder. ②...

  • Page 75: Electric Schenatic Diagram(Include Eps System)

    Electrical Power Steering System Chapter 8A Electric Schenatic Diagram(Include EPS System) 8A-5...

  • Page 76: Key Switch Removal

    Electric Component Chapter 9 WARNING • Please refer to Chapter 1 “Protection for Electrical Safety”. Key switch removal (SE) Assure that the E-Brake switch is in the middle possition(Normal). 2. Take out the key from the key switch. 3. Remove the middle electrical regaining plate. 4.
  • Page 77 Electric Component Chapter 9 Removal of forward/reverse switch (SE) 1. Assure that the E-Brake switch is in the middle possition(Normal). Please refer to Chapter 1 “Protection for Electrical Safety”. 2. Take out the key from the key switch. 3. Remove the middle electrical regaining plate. 4.
  • Page 78 Electric Component Chapter 9 Removal of emergency switch (SE) 1. Assure that the E-brake switch is in the middle possition(Normal). Please refer to Chapter 1 “Protection for Electrical Safety”. 2. Take out the key from the key switch. 3. Remove the middle el ectrical regaining plate. 4.

  • Page 79: Key Switch Installation

    Electric Component Chapter 9 WARNING • Please refer to Chapter 1 “Protection for Electrical Safety”. Key switch removal (SS/LE) 1. Assure that the E-Brake switch is in the middle possition(Normal). 2. Take out the key from the key switch. 3. Remove the front cover. 3.

  • Page 80: Removal Of Forward/Reverse Switch

    Electric Component Chapter 9 Removal of forward/reverse switch (SS/LE) 1. Assure that the E-brake switch is in the middle possition(Normal). Please refer to Chapter 1 “Protection for Electrical Safety”. 2. Take out the key from the key switch. 3. Remove the steering wheel. 4.
  • Page 81 Electric Component Chapter 9 Removal of emergency switch (SS/LE) 1. Assure that the E-Brake switch is in the middle possition(Normal). Please refer to Chapter 1 “Protection for Electrical Safety”. 2. Take out the key from the key switch. 3. Remove the middle el ectrical regaining plate. 4.

  • Page 82: Horn Removal

    Electric Component Chapter 9 Check: Refer to “Check Procedure 12 -- Battery discharge meter” in Chapter 10 1. Take out the key from the key switch. Assure that the E-Brake switch is in the middle possition(Normal). Battery discharge meter installation Back to the removal steps NOTE: The red, light blue and black wires must be...

  • Page 83: Horn Installation

    Electric Component Chapter 9 Horn installation Return to disassembling steps NOTE: The horn wire must be connected correctly. The tightening torque of the horn set bolt is: 9N·m (6.6ft·1b) Combination switch removal (SE) 1. Take out the key from the key switch. 2.
  • Page 84 link stopper Electric Component Chapter 9 Horn installation Return to disassembling steps NOTE: The horn wire must be connected correctly. The tightening torque of the horn set bolt is: 9N·m (6.6ft·1b) 1. Assure that the E-brake switch is in the middle possition(Normal).

  • Page 85: Combination Switch Installation

    Electric Component Chapter 9 7. Turn the switch lever and check the relevant gears for continuity, replace the part in case of un-continuity. Combination switch installation (SS/LE) Back to disassembling steps Controller removal 1. Take out the key from the key switch. 2.
  • Page 86 E-brake 9-7-1...
  • Page 87 Power display Speedometer accelerator Y/R Y/W Br/W B R/W Br/Y Speaker outlet F WD Switch buzzer horn switch Passing switch Headlight switch H/L beam switch Br/W Speedometer light switch 1N5402 Flaser Lg/R turn switch Key switch H/L speed switch Gen4 warning switch brake switch Charge control...

  • Page 88: Controller Installation

    Electric Component Chapter 9 10. Unscrew the 4 bolts on the controller mounting plate and remove the controller. Controller installation Back to the removal steps. Check the electric vehicle for normal operation: • When Forward/Reverse switch is on FORWARD position, make sure the electric vehicle is running forward.

  • Page 89: Charger Receptacle Removal

    Electric Component Chapter 9 Charger receptacle removal 1. Take out the key from the key switch. 2. Assure that the E-Brake switch is in the middle possition(Normal). 3. Disconnect the battery cable according to the directions. Please refer to Chapter 1 “Protection for Electrical Safety”.

  • Page 90: Battery Installation

    Electric Component Chapter 9 4. Disconnect the battery cable according to the directions. Please refer to Chapter 1 “Protection for Electrical Safety”. 5. Remove the nut on the battery hold down. 6. Remove the battery hold down 7. Remove the battery with a special battery lifting tool.

  • Page 91: Dc Converter Installation

    Electric Component Chapter 9 6. Remove the DC converter. DC converter installation Back to the removal steps. 9-11...

  • Page 92: Motor Removal

    Electric Component Chapter 9 Motor removal 1. Take out the key from the key switch. 2. Assure that the E-Brake switch is in the middle possition(Normal). 3. Hold the binding post with two wrenches; disconnect the wire from the connecting terminal of the motor.
  • Page 93 Electric Component Chapter 9 6. Inspect the E-brake device resistance is around 35 ohm. Inspect speed sendor. Removal of the speed sensor 1. Disconnect the battery cable as specified. Please refer to Chapter 1 "Protection for Electrical Safety" 2. Unplug the 4-wire connector from the hardness of the electric vehicle 3.

  • Page 94: Motor Installation

    Electric Component Chapter 9 Motor installation Back to the removal steps. NOTE: Match the marking line during motor installation. Removal of bulb of headlight and front turn signal light 1. Take out the key from the key switch. 2. Assure that the E-Brake switch is in the middle possition(Normal).

  • Page 95: Tail Light Removal

    Electric Component Chapter 9 Tail light removal Any defective or dim tail light shall be replaced. 1. Take out the key from the key switch. 2. Assure that the E-Brake switch is in the middle possition(Normal). Please refer to Chapter 1 “Protection for Electrical Safety”.

  • Page 96: High Mount Stop Lamp Disassembly

    Electric Component Chapter 9 High mount stop lamp disassembly 1. Remove the screw①. 2. Rotate the lamp receptacle; remove the wire harness with the bulb②. 3. Check the continuity, Replace the bulb assembly with wire harness in case of un-continuity②. High mount stop lamp installation Back to removal steps Wiper removal...
  • Page 97 Electric Component Chapter 9 Removal of inner mirror 1.Take out the key from the key switch. 2. Assure that the E-Brake switch is in the middle possition(Normal). 3. Take off the connector of inner mirror 4. Take off fixed nut of inner mirror 5.

  • Page 98: Chapter 10 Troubleshooting

    Troubleshooting Chapter 10 Troubleshooting Instructions Part 1 Symptom Possible causes Correction action Battery - dead Charge the battery. Check the wiring of the electric vehicle. Refer to the Battery - battery wiring wiring diagram on page 9-7. Circuit of key switch and Check the wire of key switch and accelerator switch accelerator switch for poor contact and disconnection.
  • Page 99 Troubleshooting Chapter 10 Part 1 of Troubleshooting Instructions, continue Symptom Possible causes Correction action The electric vehicle Check the wiring of the electric vehicle. Refer to Circuit – incorrect wiring can be started, but the the wiring diagram on page 9-7. motor braking device E-brake device failure or Refer to “Check Procedure 9—Motor speed...

  • Page 100: Check Procedures

    Troubleshooting Chapter 10 Check procedures With the following procedures, the entire electrical system can be checked without disassembling the electric vehicle. WARNING • If the wires are removed or replaced, make sure that the wires and harnesses are arranged and fixed correctly. Wires and harnesses not arranged and fixed correctly can result in electric vehicle failure, property damage and casualties.

  • Page 101: Check Procedure 1-Battery / Voltage Check

    Troubleshooting Chapter 10 Check Procedure 1—Battery / voltage check NOTE: to perform the following check procedures, the battery should be maintained properly and charged fully. Use a DC multimeter set to 200V, connect the black (-) probe to the negative output binding post of the battery and connect the red (+) probe to the positive wire of the battery.

  • Page 102: Check Procedure 4 - E-Brake Switch

    Troubleshooting Chapter 10 Check Procedure 4 - E-brake switch Please refer to Chapter 1 “Protection for Electrical Safety”. 1. Use a multimeter, set it at continuity testing position, connect the black (-) probe to one connecting the middle terminal of E-brake switch and put the red (+) probe on the left/right terminal on the same side. 2.
  • Page 103 Troubleshooting Chapter 10 5．When the key switch is on position OFF, the multimeter should show an open circuit condition. 6．When the key switch is on position ON, the multimeter should show a conducting state. 7．If other readings are obtained, replace the key switch. Refer to "Key switch removal" in Chapter 9. 8．If the key switch operates as above, install the instrument panel in the reverse sequence of removal and perform the following operations.

  • Page 104: Check Procedure 7--Controller Signal

    Troubleshooting Chapter 10 Check Procedure 7--Controller signal 35-wire connector of controller plug Function Key switch input signal--when the key switch is ON, the switch provides a (Pin 1)-light blue wire voltage of +48V to the controller. (Pin 2)- Green/Red wire CAN termination.

  • Page 105: Check Procedure 7A-Pin 1

    Troubleshooting Chapter 10 Check Procedure 7--Controller signal (Pin 24)-Green/Red wire CAN bus low signal. Digital pulse from speed encoder B. When motor running speed encoder (Pin 25)-Green/Yellow wire B output signal to this pin. (Pin 26)-White/red wire Encoder power supply. When controller working properly output 5V. CAN power supply.(when the controller working properly, provides 24V (Pin 28)-Brown/Yellow wire voltage to the accelerator.)

  • Page 106: Check Procedure 7B-Pin 2 And 24

    Troubleshooting Chapter 10 Check Procedure 7B—Pin 2 and 24 Please refer to Chapter 1 “Protection for Electrical Safety”. 1. Use a multimeter set at connectivity function, insert the black (-) probe of the multimeter into Pin 2 or Pin 24 ( Green/Red wire).Refer to the following Note.

  • Page 107: Check Procedure 7D-Pin 7 And 8

    Troubleshooting Chapter 10 Check Procedure 7D—Pin 7 and 8 1. Use a multimeter set at 200V DC, insert the red (+) probe of the multimeter into the E-brake Pin 1 (Red/Yellow wire). Connect the black (-) probe to the E-brake pin 2. 2.

  • Page 108: Check Procedure 7G-Pin 13

    Troubleshooting Chapter 10 Check Procedure 7G—Pin 13 1. Use a multimeter set at 20V DC, insert the red (+) probe of the multimeter into the Pin 13 (Red/White wire). Connect the black (-) probe to the negative binding post of the battery pack. 2.

  • Page 109: Check Procedure 9-Forward/R Everse Switch

    Troubleshooting Chapter 10 Check Procedure 9— F orward /Reverse switch Please refer to Chapter 1 “Protection for Electrical Safety”. 1. Disconnect the battery cable according to the directions. Please refer to Chapter 1 “Protection for Electrical Safety”. 2. Disconnect the 3 wires from the switch. Use a multimeter set at 200 Ω,connect the black (-) probe to Position 7 (or 8) of the switch, then connect the red (+) probe to Position 3 (or 4).

  • Page 110: Check Procedure 11 -- Battery Discharge Meter

    Troubleshooting Chapter 10 5. Turn the key switch to the on position. 6. When the battery is connected, use a multimeter set at 200V DC, connect the black (-) probe to the negative binding post of Battery 8 and connect the red (+) probe to the disconnected light blue terminal of the reverse buzzer.

  • Page 111: Check Procedure 12-- High Mount Stop Lamp

    Troubleshooting Chapter 10 Check Procedure 12-- High mount stop lamp Please refer to Chapter 1 “Protection for Electrical Safety”. Turn the key switch to ON, check the high mount stop lamp connector on main cable with a multimeter set at 200V DC (connect the red probe+ to green/yellow wire and connect the black probe - to black wire) while depressing the brake pedal.

  • Page 112: Troubleshooting Instructions Part 2

    Troubleshooting Chapter 10 Troubleshooting Instructions Part 2 (controller failure indication code): Faults and warnings Introduction In the event of a fault Gen4 takes the following action: 1. Protects the operator and vehicle where possible (e.g. inhibits drive). 2. Sends out an EMCY message on the CANbus. 3.
  • Page 113 Troubleshooting Chapter 10 二、LED failure diagnosis Use below to determine the type of fault from the number of LED flashes. The LED flashes a preset number of times in repetitive sequence (e.g. 3 flashes – off – 3 flashes – off – and so on). Only the faulty node in a multi-node system flashes its LED.
  • Page 114 Troubleshooting Chapter 10 Fault Level Set conditions Operator action flashes Hardware over voltage Hardware over voltage circuit Investigate and reduce activated activated battery voltage below user defined maximum level. Ensure suitable over voltage is configured in 2C01 and 4612 Hardware over current Hardware over current circuit Check motor load and trip activated...
  • Page 115 Troubleshooting Chapter 10 Fault Level Set conditions Operator action flashes Motor high voltage Capacitor voltage has entered the Reduce battery voltage protection motor high voltage cutback region below start of motor defined in 4612 high voltage cutback region. Controller high voltage Battery voltage or capacitor Isolate controller and protection with line...
  • Page 116 Troubleshooting Chapter 10 Fault Level Set conditions Operator action flashes Encoder fault Speed measurement input wire-off Check encoder wiring is detected. Over current Software has detected an over Check motor load and current condition wiring. Check motor parameters are correct. Current Control fault Software is unable to control Check motor load and...

  • Page 117: Chapter 11 Battery And Charger

    Battery and Charger Chapter 11 Battery Overview The battery provided for the electric vehicle must be able to provide all (100%) the energy it requires. Therefore, the battery will make a deep discharge of 70% to 80% of its full capacity before being recharged, which is a process named “deep cycle”.

  • Page 118: Common Misconceptions About Battery

    Battery and Charger Chapter 11 The result is two metalloids, the lead sulfate (PbSO ) immerse in water (H O). As the battery is fully discharged, no electric energy can be generated. After the connection of discharged battery and the charger, in the reverse procedures, the sulfate ion ) enters the electrolyte from the positive and negative plates to form sulfuric acid (H ).

  • Page 119: Battery Replacement

    Battery and Charger Chapter 11 The dirt and rust may form “The dirt and rust on the battery current passage, which results Self discharge will do no harm.” in the self discharge of battery. Please refer to “self discharge”. “Fill water into the battery to the In most cases, water must be liquid level in the evening.

  • Page 120: Battery Maintenance

    Battery and Charger Chapter 11 Fig 11-5: Schematic diagram of electric vehicle battery 4. Inspect and clean the battery support and hold-down gear. The nuts and bolts on the hold-down gear may rust. Therefore, it is suggested that they are cleaned on a regular basis, and be replaced when necessary.

  • Page 121: Self Discharge

    Battery and Charger Chapter 11 entering the battery. Ensure the connecting terminals are tightly secured. When all terminals are dried, apply the terminal protection oil to all the connecting terminals. Please refer to “self discharge”. 3. Maintain the electrolyte at normal liquid level. Please refer to “electrolyte liquid level”. 4.

  • Page 122: Vibration Damage

    Battery and Charger Chapter 11 liquid level benchmark. This is because the liquid level of electrolyte may rise when the battery is charged. Some electrolyte may burst out of the battery cover. Therefore, filling water to the liquid level before battery charging may result in the spillage. This will reduce the battery capacity and corrode its neighboring metal components.

  • Page 123: Battery Charging

    Battery and Charger Chapter 11 Battery charging The charger provided for the E-merge electric vehicle has brought a solution to the common problem relating to the battery charging. The charger can shut off automatically to prevent undercharge and overcharge. Meanwhile, all battery compartments are automatically distributed with balanced electric quantity by the light current in such a way to prolong the service life of the battery.

  • Page 124: Alternating Use Of Vehicles

    Battery and Charger Chapter 11 Alternating use of vehicles Use the electric vehicles alternately. In case the vehicle came back the last yesterday evening is dispatched as the first one the next morning, its battery is hard to sustain. The workload should be equally allocated so that all electric vehicles are equally used.

  • Page 125: Battery Troubleshooting Diagram

    Battery and Charger Chapter 11 Battery troubleshooting diagram The vehicle performance falls short of expectation Fully charge the battery Inspect and test the battery charger The reading is lower than 6A and the The reading is not lower than 6A. charging voltage is higher than 56V.

  • Page 126: Inspection And Test Of The Battery

    Battery and Charger Chapter 11 Inspection and test of the battery Please refer to Chapter 1 “Protection for Electrical Safety”. Carry out four inspections to find out the cause to the battery performance reduction. As these inspections are more and more detail and time-consuming, please carry out the inspection from the beginning before proceeding to other inspections until the problem is identified as shown in “battery troubleshooting diagram”...

  • Page 127: Procedures For Inspection With Hydrometer

    Battery and Charger Chapter 11 Procedures for inspection with hydrometer 1. Before inspection, first ensure that the battery has sufficient electrolyte to cover the electrode plates by about 1/2 inch (13mm) and is fully charged. In case it is a must to fill water, the batter should be recharged before the inspection with hydrometer.

  • Page 128: Discharge Test

    Battery and Charger Chapter 11 Fig 11-8: Hydrometer Measures Corrected specific gravity Vehicle Battery Electrolyte Correction should be number number temperature factor Battery 1 Battery 2 Battery 3 Battery 4 taken Normal 1.275 –.024 1.280 –.024 1.280 –.024 1.280 –.024 20°F (-6.6°C) –.024 battery-fully...

  • Page 129: Procedures For Discharge Test

    Battery and Charger Chapter 11 The discharge test is the most difficult and time-consuming test. Please use battery discharge tester. Procedures for discharge test 1. Ensure that the battery is fully charged and that the liquid level of electrolyte in battery compartment is normal.

  • Page 130: Battery Troubleshooting Example

    Battery and Charger Chapter 11 Battery voltage Battery condition 5.25V 5.25V 5.25V 5.25V 5.25V 5.25V 5.25V Very good 5.25V The service life of batter No 4 5.30V 5.30V 5.35V 5.10V 5.32V 5.33V 5.33V 5.32V is to expire. The service lives of battery No 5.50V 5.48V 5.12V 5.51V 5.08V...

  • Page 131: Battery Storage

    Battery and Charger Chapter 11 Hydrometer inspection result: Battery number Battery compartment number 1.25 Battery 1 (positive terminal 1.200* 1.260 1.270 1.275 1.265 1.270 1.275 Battery 2 1.275 1.285 1.280 1.270 1.275 1.285 1.280 1.270 Battery 3 (negative terminal 1.280 1.275 1.280 1.270...

  • Page 132: Battery Charger

    Battery and Charger Chapter 11 Battery charger Overview Journeyman charger is fully automatic and designed to charge the storage battery of the electric vehicle. The battery charger can be connected to the vehicle of any mileage, and will continue to charge the battery as long as it is not disconnected.

  • Page 133: Get To Know The Charger

    Battery and Charger Chapter 11 Fig 11-11: Electrical outlet The charger will start automatically a few seconds after the connectors are plugged in. When the storage battery is fully charged, the charger will automatically stop the charging. Unplug the DC connector to use the vehicle.

  • Page 134: Removal Of The Charger

    Battery and Charger Chapter 11 continue till the remaining cycle is completed. 3. In case the storage battery is fully charged in a very short period (less than 2 hours), the charger will shut off. In case the voltage of open circuit storage battery drops down to a point where the recharge is needed, the charger will start and charge the battery till it is fully charged.
  • Page 135 Battery and Charger Chapter 11 IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS – This manual contains important safety and operating instructions. Before using battery charger, read all instructions and cautionary markings on battery charger, battery, and product using battery. LOOK FOR THIS SYMBOL TO POINT OUT SAFETY PRECAUTIONS. IT MEANS: BE ALERT—YOUR SAFETY IS INVOLVED.
  • Page 136 Battery and Charger Chapter 11 3.Charger 3-LED display. CHARGE COMPLETE: the LED light is green, it means absorbtion phase complete or charger in Maintenance Mode. CHARGE STATUS: the LED light is amber, it means in absorbtion phase . FAULT: the LED light is red and flashing, it means charge error.Reset charge power and refer to Troubeshooting below.
  • Page 137 Battery and Charger Chapter 11 FAULTS ( 0 ) = Off ( 1 ) = On Solid N/A = Not applicable, LED state does not matter Fault Charge Status Charge Complete Description (Red) LED (Yellow) LED (Green) LED DC DISCONNECT – DC disconnect detected via the third-pin, but DC (battery) voltage is still present at the charger output.

  • Page 138: Troubleshooting

    Battery and Charger Chapter 11 TROUBLESHOOTING The charger was fully tested and calibrated before leaving the factory. It was delivered ready to charge. If properly installed, the charger should require very little attention. If improper charger operation occurs, it will require repair by a qualified service technician.

  • Page 139: On-Board Charger

    Battery and Charger Chapter 11 On-Board Charger Operation If the charger was factory-configured for on-board use, follow these operating instructions: 1. Ensure that the vehicle/equipment that the charger is mounted on is turned off. 2. With the charger AC power cord disconnected from the AC outlet, connect the charger DC output connector/plug to the battery connector/receptacle (most likely already connected or hard wired).
  • Page 140 Battery and Charger Chapter 11 . CHARGER OPERATION WARNING: TO REDUCE THE RISK OF AN ELECTRIC SHOCK, CONNECT ONLY TO A SINGLE- PHASE, PROPERLY GROUNDED (3-WIRE) OUTLET. REFER TO GROUNDING INSTRUCTIONS. CAUTION: MAKE SURE THE BATTERY IS A RECHARGEABLE DEEP-CYCLE BATTERY WITH THE PROPER RATED VOLTAGE FOR THIS CHARGER.
  • Page 141 1115 Commercial Avenue • Reedsburg, WI 53959 Phone: (608) 524-8888 • Fax: (608) 524-8380 (800)222-4653 • Web:www.columbiavehicles.com...

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