User Manuals: Columbia 1990 Electric Shuttle Vehicle

Manuals and User Guides for Columbia 1990 Electric Shuttle Vehicle. We have 1 Columbia 1990 Electric Shuttle Vehicle manual available for free PDF download: Service Manual

Columbia 1990 Electric Shuttle Service Manual (113 pages)

Brand: Columbia | Category: Offroad Vehicle | Size: 10 MB

Preparation for Service
3
Model Identification
3
Engine and Model Identification
3
Warnings and Cautions
4
Table of Contents
5
General Vehicle Information
8
Specifications
8
General Features
8
Dimensions
8
Fluids and Lubricants
9
Torques
9
Foot Pounds to Kilogrameters
9
Metric Conversion Table
10
General Information
11
Safe Operating Rules
11
Controls and Operation
11
Parcars
11
Storage
12
Directional Key Switch
12
Accelerator
12
Brake
12
Service
13
Initial Service Checks
13
Gasoline Powered Vehicles
13
Electric Powered Vehicles
13
Regular Service Intervals
14
Troubleshooting
15
Wheels, Tires and Front Hubs
20
Tire and Wheel Assembly
20
Tires
20
Front Hub
21
Break Tire Beads Free of Rim
21
Removing Upper Bead from Rim
21
Removing Lower Tire Bead from Rim
21
Steering and Suspension
23
Steering Wheel
23
Front Suspension
23
Steering Wheel Removal
23
Adjustment
24
Toe in / Toe Out/Camber
24
Camber Adjuster
24
Rack and Pinion Removal
25
Leaf Spring Removal
25
Tie Rod Removal
26
A-Arm Removal
26
Rear Suspension
26
King Pin or Steering Arm Removal
26
Replacing Rear Fork
27
Replacing Rear Springs
27
Rear Fork Bushing
27
Replacing Rear Fork Bushing
28
Frame Servicing
28
Rear Axles and Differential
29
Differential
30
Disassembling and Inspecting Differential
30
Ring Gear Runout Check
31
Ring and Pinion Backlash Check
31
Prying out Case
31
Differential Assembly
32
Recess for Puller
32
Removing Ring Gear
32
Driving out Lock Pin
33
Remove Pin Mate Shaft
33
Removing Rear Pinion Bearing Cup
33
Assembling Differential
34
Installing Pinion Mate Shaft
34
Installing Lock Pin
34
Pressing on Differential Bearings
34
Rear Axle and Differential
36
Differential Lubrication
36
Removing Rear Axle
36
Removing Rear Axle and Differential Assembly
36
Bearing Cap Identification
38
Removal of Drive Pinion Shaft Gear
39
Remove Idler Gear Shaft
39
Brakes
40
Brake Cable Removal
40
Brake Adjustment
40
Brake Cable Removal and Adjustment
40
Hand Parking Brake
41
Hand Parking Brake Adjustment
41
Parking Brake Adjustment
41
C6E Hand Brake
41
Body
42
Windshield
42
Seat and Handrails
42
Parcar & Columbia Shuttle
42
Front Housing Removal
43
Rear Body
43
Angle Bag Rack
43
Stand-Up Bag Rack
44
Parcar Engine
45
Description and Operation
46
Engine Removal
46
Inspection and Repair of Motor Mounts
47
Cylinder and Piston
47
Cylinder Head Removal
48
Connecting Rod Inspection
48
Piston Pin Removal
48
Cleaning and Inspection
49
Cylinder Head
49
Measuring Cylinder and Piston
49
Fitting Piston in Cylinder
50
Cylinder Bore Measurement
50
Measuring Piston
50
Piston Rings
51
Ring Side Clearance
51
Ring End Gap
51
Piston Pin and Bearing
52
Crankcase
52
Crankshaft Disassembly
54
Crankshaft Assembly
54
Truing Crankshaft
55
Crankshaft Runout
55
Correcting Crankshaft Misalignment
55
Fuel System
57
Carburetor
57
Low Speed Adjustment
58
Throttle Stop Screw Adjustment
58
Float Level Adjustment
59
Governor Control Adjustment
59
Throttle Control Link Adjustment
59
Carburetor Removal
61
Float Chamber
62
Carburetor Body
62
Fuel Pump
62
Carburetor Troubleshooting
64
Reed Valve
66
Cleaning, Inspection and Repair
66
Air Cleaner
66
Fuel Tank
67
Oil Injection Pump
68
Bleeding Oil Injection Lines
69
Ignition Timer Wire Routing
69
Transmission
70
Drive Belt
70
Primary Drdive
70
Primary Tool
71
Secondary Drive
73
Bushing Removal
73
Secondary Drive Assembly
73
Electrical
75
Testing Directional Key Switch for Continuity
75
Solenoid Testing
76
Accelerator Microswitch
76
Solid State Ignition
78
Ignition Coil
78
Spark Plugs
80
Spark Plug Conditions and Analysis
80
Core Bridging, Gap Bridging
80
Testing Spark Plugs
81
Setting Spark Gap
81
Wet Fouling
81
Overheating
81
Starter-Generator
82
Installing Spark Plugs
82
Starting Circuit Test
82
Charging Circuit Test
83
Starter-Generator Removal
83
Holding Brushes off Commutator
84
Starter-Generator Disassembly
84
Testing Brushes
85
Cleaning and Inspection Brush Springs
85
Visual Inspection of Armature
85
Armature Ground Test
86
Armature Short Test
86
Armature Coil Balance Test
87
Grounded Field Test
87
Refinishing Commutator
87
Recessing the Mica Separators
87
Visual Inspection of Field Coils
88
Open Field Test
88
Voltage Regulator
89
Gasoline Vehicle Battery
89
Testing Voltage Regulator in Vehicle
89
Antidote
90
Battery in Vehicle
91
Battery out of Vehicle
91
Electric Vehicle Battery
92
Load Testing
92
Voltage Requirements at Ambient Temperatures
92
Conditions Which Affect Charging
94
Overall Battery Bank Condition after Charging
94
Testing Battery
94
Specific Gravity Test
95
Using the Hydraulic Meter
95
Preparation for Discharge Test
96
Discharge Test Procedure
96
Storing Batteries
96
Interpretation of Discharge Test Results
96
Component Operation
97
Electronic Speed Control Adjustment
97
Solenoid
97
Motor Resistor
97
Electrical Operation and Circuits
98
To Adjust Speed Control
98
Bench Testing Components
101
Key Switch
101
Electric Motor
101
Motor Assembly
103
Armature Inspection
104
Commutator Inspection and Reconditioning
104
Inspection of Field Windings
104
Bearing Inspection
104
Motor Terminal Identification
105
Front of Vehicle
106

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User Manuals: Columbia 1990 Electric Shuttle Vehicle

Columbia 1990 Electric Shuttle Service Manual (113 pages)

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