Columbia ParCar GD4 Manuals

Manuals and User Guides for Columbia ParCar GD4. We have 1 Columbia ParCar GD4 manual available for free PDF download: Service Manual

Columbia ParCar GD4 Service Manual

Columbia ParCar GD4 Service Manual (237 pages)

Gasoline and Electric Golf and Industrial Four Wheel Vehicles

Brand: Columbia ParCar | Category: Golf Cars | Size: 7 MB

Table of Contents

Safety
3
- Table of Contents
  4
- Notes, Cautions, Warnings and Dangers
  6
- Overview
  6
- General and Maintenance Information
  10
- Vehicle and Model Information
  12
- Vehicle Identification Number (VIN) Matrix
  13
- General Vehicle Specifications
  14
- Controls and Operation
  17
- Location of Controls
  17
- Notes from General Vehicle Specifications
  17
- Safety Committee
  17
- Pre-Operations Inspections
  18
- Pre-Operations Check List
  19
- What to Do if You Find a Problem
  19
- Torque Table
  20
- Torques and Metric Conversion Factors
  20
- Conversion Factors
  21
- Floor Jack
  21
- Hoist Lifts
  21
- Lifting Instructions
  21
- Gasoline Vehicles
  22
- Hydraulic Floor Lift - Frame Lift
  22
- Jack Stands
  22
- Vehicle Storage
  22
- Electric Vehicles
  23
- Preparing Vehicle for Extended Storage
  23
- Returning Vehicle to Service
  23
- Powermaster Towing Instructions
  24
- Towing and Transporting Vehicles
  24
- Maintenance Schedule Checklist
  25
- Periodic Maintenance
  25
- Periodic Service Calendar
  25
- Air Filtration System
  27
- Chassis Lubrication
  27
- Engine Cooling
  27
- Gas Vehicles
  27
- Air Cleaner Assembly
  28
- Engine Oil
  29
- Fuel and Oil Recommendations
  29
- Sae Viscosity Grades
  29
- Check Oil Level
  30
- Cooling System
  30
- Engine Oil, Lubrication
  30
- Maintenance
  30
- Accelerator Micro Switch Adjustment
  31
- Accelerator/Throttle System Overview
  31
- Adust Accelerator Micro Switch
  31
- Differential Oil Fill and Check Hole
  31
- Adjust Accelerator Cable
  32
- Adjust Throttle Cable
  32
- Cable Adjustment - Typical
  32
- Throttle Cable Connection to Carburetor
  32
- Governor Arm & Spring
  33
- Governor Components
  33
- Governor System
  33
- Periodic Maintenance and Inspection
  33
- Battery Charging
  34
- Electric Vehicle (EV) Charger Operation
  34
- Electric Vehicle Service
  34
- Governor Adjustment
  34
- Prolonging Battery Life
  35
- Battery Cleaning
  36
- Battery Watering
  36
- Electric Vehicle Recommended Maintenance Procedures
  36
- Bodies, Seats & Components
  37
- Chassis Lubricaton
  37
- Front Body Removal
  37
- Refinishing
  37
- Bag Rack
  38
- MID and Rear Bodies
  38
- MID-Body - Golf/Commercial
  38
- Seat and Handrail
  38
- Body Guides
  39
- Front Hinge Brackets
  39
- Industrial Rear Bodies
  39
- Rear Body Hinge
  39
- Steering, Suspension, & Frame
  41
- Adjustment and Service Specifications
  43
- General Information
  43
- Steering and Suspension
  43
- Steering System
  43
- Steering Wheel
  43
- Disconnect Steering Shaft
  44
- Disconnect Tie Rod Ends
  44
- Front Wheels and Hubs
  44
- Rack and Pinion Steering Assembly
  44
- Front Hub Removal
  45
- Front Suspension
  45
- Front Wheel Hub
  45
- Bearing Replacement
  47
- Center Leaf Spring
  47
- Rack and Pinion Assembly
  47
- Rack and Pinion Assembly Repair
  47
- Camber Adjustment
  48
- Steering and Suspension Adjustment
  48
- Tire and Wheel Assembly
  48
- Break Bead of Tire from Wheel
  49
- Remove Tire
  49
- Rear Springs
  50
- Rear Suspension
  50
- Shock Absorbers
  50
- Tire Inflation
  50
- Engine Mount Plate Assembly
  51
- Rear Fork
  51
- Rear Fork Bushing and Bolt
  51
- Frame
  52
- Servicing
  52
- Brake Systems
  53
- Table of Contents
  54
- Annual Maintenance Inspection
  55
- Mechanical Braking System
  55
- Mechanical Drum Brake Assembly
  55
- System Overview
  55
- Brake Cables
  57
- General
  62
- Hydraulic Drum Brake Components
  62
- Brake Drum Service
  63
  - Wheel Cylinder Components
    63
  - Wheel Cylinder Service
    63
  - Bleeding Hydraulic System
    64
  - Brake Fluid Maintenance
    64
- Hydraulic Master Cylinder
  64
- Bleeder Fitting
  65
- Trouble Shooting
  65
- Disc Brake Components
  66
- Hydraulic Disc Brake System
  66
- Periodic Maintenance Inspection
  67
  - Brake Caliper Service
    68
  - Brake Disc Service
    68
- Disc Brake Service
  68
- Brake Fluid Maintenance
  69
- Remove Disk Brake Pad
  69
- Disc Brakes
  70
Hydraulic System Master Cylinder
69
Torque Converter/Transmission System
71
- Torque Convertor Transmission
  72
- Drive Belt
  72
- Drive Clutch
  72
- Operation of Drive System
  72
- Primary Drive Assembly
  73
- Clutch Sheave Wear
  73
- Secondary Driven Clutch
  74
- Cam Shoe Inspection
  74
- Torque Converter/Transmission Alignment
  75
- Transmission Shift System and Final Drive Axles
  76
- Transmission Shift System
  77
- Overview of Operation
  77
- Console Shift Assembly
  77
- Starting System Lockout
  77
- Console Shifter Assembly
  78
- Console Shifter Adjustment
  78
- Remove and Install Shift Cable
  78
- Shift Cable Adjustment
  79
- Minor Adjustment
  79
- Route Cable to Passenger Side, Frame Rail
  79
- Transaxle Shift Bracket and Springs
  79
- Removal of Transaxle
  80
- Body Hinge
  80
- Service Procedure for Transaxle Assembly
  80
- Gas Vehicle Final Drive Axle Assembly
  80
- Throttle Cable
  81
- Transaxle Shift Lever and Springs
  81
- Remove Drive Belt
  81
- Jack Stand under Fork Tube
  81
- Remove Wheel
  82
- Remove ‘E’ Clips
  82
- Remove Transaxle Mount Bolts
  82
- Drain Oil
  82
- Remove Counter Shaft, Gear and Spacer
  83
- Case Bolts
  83
- Governor
  83
- Protect Shaft
  83
- Removing Input Shaft
  84
- Remove Snap Ring from Axle Housing
  84
- Input Shaft Assembly
  84
- Remove Axle from Case
  84
- Differential
  85
- Differential Components
  85
- Center Shaft Assembly When Disassembled
  85
- Assembly of Transaxle
  85
- Assembly Input Shaft
  86
- Differential Assembly
  86
- Spring Pin
  86
- Center Shaft Assembly
  86
- Differential Gear
  87
- Governor Fork Assembly
  87
- Center Shaft Assembly with Shift Fork
  87
- Assemble Gear Case
  87
- Bolt Diagram
  88
- Installation of Axle Assembly
  88
- Install Counter Shaft Assembly
  88
- Position Spacer
  88
- Gas Vehicle Final Drive Assembly
  90
- Precautions for Disassembly
  90
- Bearings and Seals
  90
- Snap Rings
  90
- Exploded View
  91
- Remove Detent Screw
  92
- Remove Axle and Axle Housing
  92
- Support with Input Shaft down
  92
- Remove Housing Bolt
  92
- Carrier Assembly with Right Case
  93
- Remove Differential
  93
- Carrier Half Without Differential
  93
- Disassemble Intermediate Shaft
  93
- Remove Input Shaft
  94
- Reverse Idler Gear and Washer
  94
- Remove Reverse Idler Gear
  94
- Remove Snap Ring
  94
- Remove Governor Shaft
  95
- Input Shaft and Components
  95
- Remove Governor Backing Plate
  95
- Assemble Governor Backing Plate
  95
- Remove Bearings
  96
- Remove Differential Gear
  96
- Install Oil Seals
  96
- Install Bearings
  96
- Install Governor Shaft
  97
- Install Governor Lock Pin
  97
- Install Shift Actuator Shaft
  97
- Install Input Shaft
  97
- Install Snap Ring
  98
- Install Intermediate Shaft and Fork
  98
- Install Detent Ball, Spring and Screw
  98
- Install Intermediate Shaft Components
  98
- Torque Axle Housing Bolts
  99
- Install Differential Assembly
  99
- Torque Carrier Bolts
  99
- Electric Vehicle Final Drive Axle Assembly
  100
- General Precautions for Disassembly
  100
- Cleaning and Inspection
  100
- Oil Check and Change Intervals
  100
- Axle Components
  102
- Outer Snap Ring Removal
  102
- Spindle Nut Removal
  102
- Axle Shaft, Bearing, and Oil Seal
  102
- Axle Bearing Removal
  103
- Cover Plate Screws Removal
  103
- Separate Cover Plate from Housing
  103
- Bearing Caps Removal
  103
- Differential Bearings Removal
  104
- Remove Gear from Differential Case
  104
- Remove Dust Cover
  104
- Snap Ring Removal
  104
- ‘O’ Rings Removal
  105
- Intermediate Bearings Removal
  105
- Input Shaft Removal
  105
- Intermediate Shaft “O” Ring Removal
  105
- Input Shaft Bearing Installation
  106
- Reinstall Input Shaft
  106
- Install Outer Snap Ring
  106
- Differential Gear Assembly
  106
- Install Differential Case
  107
- Seal and Install Cover Plate
  107
- Install Dust Cover Plugs
  107
- Install Shaft Seals
  107
- Gas & Electric Heavy Duty Axle Shaft & Bearing Service
  108
- Components of the One-Piece Shaft
  108
- Brake Drum Removal
  108
- Remove Brake Assembly Hardware
  108
- Center Punch Retaining Ring
  109
- Drill Retaining Ring
  109
- Remove Axle and Brake Assembly
  109
- Inner Axle Shaft Seal Removal
  109
- Components of One-Piece Axle Shaft
  110
- One-Piece Axle Shaft
  110
- Axle and Brake Assembly Components
  110
- Support Bearing Assembly
  110
- New Grease Seal Assembly
  111
- Install Axle and Brake Assembly
  111
- Press Retaining Rings
  111
- Place Retaining Ring on to Axle
  111
- Columbia Parcar/Briggs & Stratton Engines
  112
- Handy Repair Check Chart
  120
- In the Interest of Safety
  122
- Theory of Operation
  123
- Gasoline
  123
- Oil Viscosity Grades
  123
- Oil, Lubrication
  124
- Change Oil (Crankcase)
  124
- Dipstick and Oil Fill Tube
  124
- Tune-Up Procedure
  125
- Overhaul Procedure
  126
- Check Carburetion
  128
- Check-Up
  128
- Check Ignition (Using Engine Starter)
  128
- Check Compression
  128
- Carburetor, 9 & 13 H.p. Engines
  129
- Carburetor, Theory of Operation
  129
- Float System Operation
  129
- Idle System Operation
  129
- Part Throttle Operation
  130
- High Speed System Operation
  130
- Choke System Operation
  130
- Service Briggs & Stratton/ 9 H.p. Carburetor - (Mikuni Carburetor)
  131
- Removing Fuel Hose and Clamp
  131
- Removing Bowl
  131
- Removing Bowl Gasket
  131
- Removing Pilot Jet
  132
- Removing Limiter and Idle Mixture Valve
  132
- Nozzle Removal
  132
- Removing Main Jet and Nozzle
  132
- Assemble Carburetor - 9 H.P. Engine
  133
- Remove Throttle Valve and Shaft
  133
- Clean Fuel System
  133
- Install Choke Shaft and Valve
  134
- Install Pilot Jet
  134
- Install Idle Mixture Valve
  134
- Install Float Bowl Gasket
  135
- Assemble Float Needle and Float
  135
- Install Float Assembly
  135
- Inspect Float Setting
  136
- Install Main Nozzle and Jet
  136
- Installing Carburetor Nozzle and Main Jet, High Altitude Compensation
  136
- Installing Bowl
  136
- Installing Carburetor Spacer
  137
- Carburetor Intake Elbow
  137
- Carburetor Installation
  137
- Carburetor Adjustment
  137
- Service Carburetor - 13 H.p. (Walbro Carburetor)
  138
- Adjusting Idle Mixture and Speed
  138
- Installing Idle Mixture Screw, Limiter Cap
  138
- Outside View, Carburetor - Typical
  138
- Choke Shaft
  139
- Removing Throttle Shaft
  139
- Disassemble Carburetor
  139
- Remove Carburetor - 13 H.P. Engine
  139
- Assemble Carburetor
  140
- Remove Fuel Inlet Seat
  140
- Clean and Inspect Carburetor
  140
- Install Welch Plug
  140
- Install Fuel Inlet Seat
  141
- Install Choke Shaft
  141
- Install Throttle Shaft
  141
- Install Main Nozzle
  141
- Install Idle Screw
  142
- Install Inlet Needle Valve and Float
  142
- Main Jets
  142
- Fuel Pump Removal
  143
- Installing Limiter Cap
  143
- Remove Fuel and Vacuum Line
  143
- Fuel Pump
  143
- Inline Fuel Filter Service
  144
- Fuel Pump Installation
  144
- Inspect Fuel Tank
  144
- Fuel Tank Removal
  144
- Magnetron Ignition
  145
- Ignition System
  145
- Spark Plug Maintenance
  145
- Check Ignition
  145
- Removing Spark Plug Elbow
  146
- Removing Ignition Armature, Typical
  146
- New Style Flywheel Puller
  146
- Pulling Flywheel, Typical
  146
- Oil Sensor Wiring
  147
- Install Magnetron Armature
  147
- Torquing Flywheel, Typical
  147
- Install Flywheel
  147
- Spark Plug Wire Routing
  148
- Wire Routing, Typical
  148
- Installing Spark Plug Elbow
  148
- Installing Armature
  148
- Install Fan Housing
  149
- Magnet under Armature
  149
- Engine Ground Wire
  149
- Installing Oil Gard Bracket, Typical
  149
- Engine Removal and Installation
  150
- Breather Hose Removal
  150
- Remove Fuel Line at Carburetor
  150
- Remove Engine Ground Lead
  150
- Engine Mount Bolts
  151
- Installing Clamping Tool
  152
- Compression Testing
  152
- Engine Alignment
  152
- Setting Tester
  153
- Cylinder Head
  153
- Pre-Setting Regulator
  153
- Prepare Cylinder Head for Removal
  153
- Removing Valve Cover, Typical
  154
- Removing Cylinder Head, Typical
  154
- Removing Rocker Nuts, Typical
  154
- Removing Rocker Arm Shaft
  154
- Valve Guide Service
  155
- Valve Service
  155
- Removing Valves
  155
- Valve and Seat Dimensions
  155
- Installing Push Rod Guide and Studs
  156
- Torque Pattern, Cylinder Heads
  156
- Installing Rocker Balls and Screws, Typical
  156
- Install Rocker Arm Shaft - 13 H.P. Engines
  157
- Adjusting Valve Clearance
  157
- Install Rocker Arms - 9 H.P. Engines
  157
- Adjust Valve Clearance - 9 and 13 H.P. Engines
  157
- Install Valve Cover
  158
- Valve Cover Torque Sequence, Typical
  158
- Valve Seat Width
  158
- Rocker Arm Stud or Shaft Torque
  158
- Remove Breather (Valve Cover)
  159
- Check Breather (Valve Cover)
  159
- Lubrication System
  159
- Breathers
  159
- Optional Oil Gard Systems
  160
- Oil Dipper Lubrication
  160
- Oil Dipper Inspection
  160
- Principles of Operation
  160
- Engine Starts, and Dies, or will Not Start
  161
- Disassemble OIL GARD Low Oil Warning System
  161
- Inspect OIL GARD Low Oil Warning System
  161
- Assemble OIL GARD Low Oil Warning System
  161
- Inspect Piston Ring Groove Wear
  162
- Remove Connecting Rod and Piston Pin
  162
- Pistons, Rings, and Connecting Rods
  162
- Inspect Connecting Rod
  163
- Inspect Piston Pin and Piston Pin Bore
  163
- Assemble Piston and Connecting Rod
  163
- Inspect Piston Ring End Gap
  163
- Install Connecting Rod and Piston
  164
- Ring Compressor
  164
- Installing Piston Assembly
  164
- Rod and Cap Alignment
  164
- Connecting Rod Screw Torque
  165
- Crankshafts & Cam Gears
  165
- Piston Pin & Piston Pin Bore Reject Size
  165
- Connecting Rod Reject Sizes
  165
- Inspect Crankshaft
  166
- Check Cam Gear
  166
- Polish Crankshaft Journals
  166
- Install Crankshaft
  166
- Cam Gear Reject Sizes
  167
- Check Crankshaft End Play
  167
- Adjust Crankshaft End Play
  167
- Install Crankcase Cover
  167
- Cylinders
  168
- Checking Cylinder Bore
  168
- To Set up for Honing
  168
- Resizing
  168
- To Hone Cylinder
  169
- Cylinder Finish (Cross Hatch)
  169
- Honing Set-Up, Example
  169
- Cylinder Hones
  169
- Cross Hatch
  170
- Cylinder Cleaning
  170
- Check Ball Bearings
  170
- Check Cam Gear Bearings
  170
- Install Magneto Ball Bearing - 9 H.P. Engines
  171
- Remove PTO Ball Bearing - 9 H.P. Engines
  171
- Install PTO Ball Bearing - 9 H.P. Engines
  171
- Installing Bearing - Mag. Side
  171
- Removing Bearing - Mag. Side
  172
- Installing Bearing - PTO Side
  172
- Remove Magneto Ball Bearing - 13 H.P. Engines
  172
- Bearing Removal Tool Components
  173
- Removing Bearing - PTO Side
  173
- Bearing Installation Tools Components
  173
- Bearing Removal Tools Components
  173
- Oil Seals
  174
- Crankcase Cover
  174
- Removing Ball Bearing
  174
- Specification Tables
  175
- Standard Bore
  175
- Remove Rotating Counterweight Shaft
  175
- Exhaust System
  176
- Inspect Counterweight Shaft
  176
- Install Rotating Counterweight Shaft
  176
- Removal of Exhaust System
  176
- Engine Exhaust Pipe
  177
- Remove Worm Gear Clamps
  177
- Remove Choke Cable from Muffler
  177
- Installation of Exhaust System
  177
- Electrical Systems & Components
  183
- Gas Vehicle Electrical System & Components
  186
- Micro Switches
  186
- Accelerator Micro Switch
  186
- Gas Vehicle Schematic
  186
- Gas Vehicle Key Switch
  187
- Console Shifter Micro Switch Adjustment
  187
- Adjust Micro Switch Position
  187
- Electrical System Testing
  188
- Vehicle “Clicks”, but Starter Does Not Spin Engine
  188
- Vehicle will Not Click or Spin Engine to Start (Forward or Reverse)
  189
- Vehicle Operates in Forward Only, Not in Reverse
  190
- Vehicle Operates in Reverse Only, Not in Forward
  190
- Reverse Alarm Operates in Forward and Reverse
  191
- Charging Circuit Test
  192
- Voltage Regulator
  192
- Engine Kill Circuit
  192
- Diode Testing
  192
- Voltage Regulator Removal
  193
- Voltage Regulator Installation
  193
- Starter/Generator
  193
- Starter-Generator
  194
- Holding Brushes off Commutator
  194
- Removing Armature Bearings
  194
- Inspecting Brushes
  195
- Minimum Brush Length
  195
- Brush Springs
  195
- Armature Inspection
  195
- Armature Ground Test
  196
- Armature Short Test
  196
- Armature Coil Balance Test
  196
- Open Field Test
  197
- Refinishing Commutator
  197
- Grounded Field Test
  197
- Field Coil Inspection
  197
- Battery, Gasoline Vehicle
  199
- Antidote
  199
- Visual Inspection and Maintenance
  199
- Load Testing
  200
- Storage
  200
- Battery Removal
  200
- Electric Vehicle Electrical Systems and Components
  201
- Electric Vehicle Battery
  201
- Minimum Voltage (12 Volt Batteries)
  201
- Conditions Which Affect Charging
  202
- Battery Electrolyte Level
  202
- Testing Battery
  203
- Specific Gravity Test
  203
- Using the Hydrometer
  203
- Preparation for Discharge Test
  204
- Interpretation of Discharge Test Results
  204
- Discharge (Load) Test
  204
- Interpretation of Hydrometer Readings
  204
- Key Switch
  205
- Storing Batteries
  205
- Solenoid
  206
- Motor Resistor
  206
- Speed Switch (Pot Box)
  206
- Key Switch Test (Electric Vehicles)
  206
- Speed Switch Assembly
  207
- Pot Switch Test
  207
- Micro Switch Test
  207
- Pot Switch Wires
  208
- Pot Switch Adjustment
  208
- Traction Motor
  209
- Speed Switch Assembly Adjustment
  209
- External Motor Inspection
  209
- Internal Motor Inspection
  210
- Motor Disassembly
  210
- Remove Armature
  210
- Shorted Armature Test
  211
- Armature Testing
  211
- Brush Removal
  211
- Growler Test of Armature
  212
- Brushes
  212
- Bearings
  212
- Frame & Field Coil
  213
- Terminal Assembly and Torque
  213
- Press Bearing and End Cover on to Armature
  214
- Motor Installation
  214
- Torque Motor Terminals
  214
- Check Speed Control Adjustment
  215
- Adjust Speed Control
  215
- Electrical Operation and Circuits
  215
- XP Speed Control System (Soft Start System)
  215
- Second Speed
  216
- Third Speed
  216
- Reverse
  216
- Trouble Shooting Guide - XP Speed Control System
  217
- Vehicle Does Not Operate, Forward or Reverse.
  217
- No Second and Fourth Speed, Operates Correctly in First and Third
  218
- Vehicle Does Not Operate in Reverse, Operates Correctly in Forward
  218
- No First and Third Speed, Operates Correctly in Second and Fourth
  218
- No First and Second Speed, Operates Correctly in Third and Fourth.
  218
- No Third and Fourth Speed, Operates Correctly in First and Second
  219
- No Fourth Speed, Operates Correctly in First, Second, and Third
  219
- Vehicle Continues to Operate, Accelerator Released
  219
- Vehicle Continues to Operate, Key Switch and off Position
  219
- XP Speed Control Wire Diagram
  220
- XP Plus System (Curtis System)
  221
- Speed Control Switch (Pot Box)
  221
- Trouble Shooting Guide - XP Plus Speed Control System
  222
- XP Plus Speed Control Wire Diagram
  226
- Power Master System
  227
- Power Master System Testing
  228
- Test Voltage at Harness Plug
  228
- Speed and Directional Circuit Testing
  229
- Power Master System Wiring Diagram
  234

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