Columbia ParCar Expediter EX21-24S User manual

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

Table of Contents
GENERAL
This service manual has been prepared with two purposes.
First, it will introduce the trained maintenance professional to
the latest field tested and factory approved major repair
methods. Secondly, it will acquaint the reader with the
construction of the Columbia ParCar vehicles and assist
him/her in performing basic maintenance and repair. We
sincerely believe that this manual will make the association
with Columbia ParCar vehicles a more pleasant and
profitable experience.
In addition to the information given in this manual, Service
Bulletins are issued to Columbia ParCar dealers which cover
interim engineering changes and supplementary
information. Service Bulletins should be consulted for
complete information on the models covered by this manual.
To ensure the safety of those servicing our vehicles and to
protect the vehicles from possible damage resulting from
improper service or maintenance, the procedures in this
manual should always be followed exactly as specified.
Execution of the procedures and troubleshooting tips as
outlined will ensure the best possible service from the
vehicle(s). To reduce the chance of personal injury and/or
property damage, carefully observe the DANGER,
WARNING, CAUTION & NOTICE recommendations
throughout this manual. See Section 1 Safety for additional
details.
To the best knowledge of Columbia ParCar Corp., the
material contained herein is accurate as of the date this
publication was approved for printing. Columbia Par-Car
Corp. is not liable for errors in this manual or for incidental or
consequential damages that result from the use of the
material in this manual. Columbia ParCar Corp. reserves the
right to change specifications, equipment or designs at any
time without notice and without incurring obligation.
PREPARATION FOR SERVICE
Proper preparation is very important for efficient service
work. A clean work area at the start of each job will allow you
to perform the repair as easily and quickly as possible, and
reduce the incidence of misplaced tools and parts. Columbia
ParCar vehicles that are excessively dirty should be cleaned
before work begins. Cleaning will occasionally uncover
trouble sources.
Tools, instruments and parts needed for the job should be
gathered before work is started. Interrupting a job to locate
tools or parts is a needless delay. Special tools required for
a job are listed at the beginning of each section.
MODEL IDENTIFICATION
Always give the vehicle identification number (VIN) when
ordering parts or making inquiries about the vehicle. Use of
the full and complete vehicle identification number will
ensure that the dealer or service provider is supplying you
with the correct parts for the vehicle. See Section 2General
Information for VIN location and additional information.
USE GENUINE REPLACEMENT PARTS
When replacement parts are required, use only genuine
Columbia ParCar parts or parts with equivalent
characteristics including type, strength and material.
Failure to do so could result in product malfunction and
possible injury to the operator and/or passenger.
To ensure a satisfactory and lasting repair, follow the service
manual instructions carefully and use only genuine Columbia
ParCar vehicle replacement parts. This is the insurance that
the parts you are using will fit right, operate properly and last
longer. When you use genuine Columbia ParCar vehicle
parts, you use the best.
PRODUCT REFERENCES
When reference is made in this manual to a specific brand
name product, tool or instrument, an equivalent product, tool
or instrument may be used in place of the one mentioned.
SECTION 1 - SAFETY
Overview .............................................................. 1-1
Safety Information ................................................ 1-1
Antidotes .............................................................. 1-1
Safety Preparations .............................................. 1-2
Decals .................................................................. 1-2
SECTION 2 - GENERAL INFORMATION
Vehicle Description ............................................... 2-1
Vehicle Identification Number (Vin) ...................... 2-1
Vin Matrix.............................................................. 2-1
Safety Committee ................................................. 2-2
Operation .............................................................. 2-2
Vehicle Specifications ........................................... 2-2
Vehicle Controls .................................................. 2-3
Pre-Operation Inspections .................................... 2-4 Pre-
Operation Checklist. ...................................... 2-4
SECTION 3 –MAINTENANCE
Electric Vehicle Service ........................................ 3-1
Periodic Maintenance ........................................... 3-1
Batteries ............................................................... 3-3
Chassis Lubrication .............................................. 3-3
Wheel Hub ............................................................ 3-3 Brake
Pedal .......................................................... 3-3 Rear Axle
.............................................................. 3-3 Chassis
Cleaning .................................................. 3-3 Seat Cleaning
....................................................... 3-3
Lifting Instructions ................................................. 3-3

Table of Contents
Tools Required ..................................................... 3-3 Hoist
Lifts .............................................................. 3-4
Hoisting the Rear of Vehicle .................................
3-4 Hoisting the front of Vehicle ..................................
3-4
Floor Jack Procedure ........................................... 3-4
Lifting the Rear of Vehicle .................................... 3-4
Lifting the Front of Vehicle .................................... 3-4
Jack Stands .......................................................... 3-4
Vehicle Storage .................................................... 3-4
Returning Vehicle To Service ............................... 3-5
Transporting the Vehicle ....................................... 3-5
Torques and Metric Conversion Factors ............... 3-6
SECTION 4 - TROUBLE SHOOTING
Pre-Troubleshooting Steps ................................... 4-1
Battery Testing ..................................................... 4-1
Troubleshooting Specific Complaints ................... 4-2
Troubleshooting with PCPAK ............................... 4-2
Troubleshooting with handheld Calibrator ............ 4-4
Vehicle Drives Slowly ........................................... 4-5
Vehicle Drives in Forward or Reverse Only .......... 4-5
Vehicle Drives but Operation
is Jerky or Inconsistent ......................................... 4-5
Vehicle Power Cuts Out ....................................... 4-5
Flash Codes and
Corrective/Investigative Action ............................. 4-6
Component Troubleshooting ................................ 4-7
SECTION 5 –ACCELERATOR & BRAKE SYSTEM
Accelerator Pedal .................................................. 5-1
Mechanical Brake System..................................... 5-1
General ................................................................. 5-1
Periodic Brake Inspection ..................................... 5-1
Annual Brake Inspection ....................................... 5-1
Mechanical Rear Drum Brake ............................... 5-2
Disassembly .......................................................... 5-2
Brake Drum Service .............................................. 5-3
Reassembly .......................................................... 5-3
Brake Strip Replacement ...................................... 5-4
Mechanical Brake Adjustments ............................. 5-4
Linkage Adjustment .............................................. 5-4
Drum Brake Shoe Adjustment ............................... 5-5
SECTION 6 - FRONT WHEELS, FORK & STEERING
General ................................................................. 6-1
Front Wheels and Hubs ........................................ 6-1
Inspecting/Replacing Wheel Hub Bearings ........... 6-2
Roller Bearings ..................................................... 6-2
Installing Front Wheel Hubs And Wheels .............. 6-2
Tires ...................................................................... 6-2
Tiller Equipped Model ........................................... 6-2
Removing Tiller ..................................................... 6-2
Replacing Steering Shaft Bearings ....................... 6-2
Installing Tiller ....................................................... 6-3
Steering Wheel Equipper Model ........................... 6-3
Removing Steering Wheel .................................... 6-3
Replacing Steering Shaft Bearings ....................... 6-3
Installing Steering Wheel ...................................... 6-3
Upper Steering Group ........................................... 6-3
Disassembly .......................................................... 6-3
Assembly .............................................................. 6-3
Front Suspension Fork –3 Wheel ......................... 6-4
Removal ................................................................ 6-5
Installing ................................................................ 6-5
Front Non-suspension Fork –3 Wheel ................. 6-5
Front Suspension –4 Wheel ................................. 6-5
Replacing Tie Rods ............................................... 6-5
Replacing Bushings .............................................. 6-7
SECTION 7 - REAR WHEELS, REAR SUSPENSION &
AXLE ASSEMBLY
Rear Wheels ......................................................... 7-1
Removing Rear Wheels ........................................ 7-1
Rear Axle Wheel Bearings .................................... 7-1
Installing Rear Wheels .......................................... 7-1
Tires ...................................................................... 7-1
Rear Suspension .................................................. 7-1
Replacing Rear Shock Absorbers ......................... 7-1
Replacing Rear Springs ........................................ 7-1
Rear Axle Assembly .............................................. 7-2
Removing Rear Axle ............................................. 7-2
General ................................................................. 7-3
Torques ................................................................. 7-3
Disassembling Rear Axle ......................................
7-5 Assembling Rear Axle ...........................................
7-8
Installing Rear Axle ............................................... 7-10
Rear Axle Differential Oil ....................................... 7-10
Changing Differential Oil ....................................... 7-10
SECTION 8 –BODY & CHASSIS
Front Bumper........................................................ 8-1 Horn
...................................................................... 8-1
Cargo Deck........................................................... 8-1
Controls and Console ........................................... 8-1
Battery Charger Indicator ..................................... 8-1
Hour Meter............................................................ 8-1
On/Off Key switch ................................................. 8-1
Directional Key Switch .......................................... 8-1
Horn Button .......................................................... 8-2 Seats
.................................................................... 8-2
Seat Back ............................................................. 8-2
Handrails .............................................................. 8-2
Brake Light ........................................................... 8-3
Fuse Block ............................................................ 8-3
SECTION 9 –BATTERIES & BATTERY CHARGER
Important Information ........................................... 9-1
Safety Information ................................................ 9-1
Antidotes .............................................................. 9-1
Battery Inspection & Maintenance ........................ 9-1
Battery Cleaning ................................................... 9-1

Table of Contents
Battery Service (Water) ........................................ 9-2
Adding Water ........................................................ 9-2
Single Point Watering System .............................. 9-2
Battery Charging ................................................... 9-3
Charger Safety Information ..................................
9-3 Battery Brand Algorithms ......................................
9-4 Delta-Q Charger Operation...................................
9-5
Single LED Display ............................................... 9-6 Red
Light Charger Error Codes ............................ 9-6 Charging
Procedure ............................................. 9-6
Testing Batteries ................................................... 9-6
Specific Gravity Test ............................................. 9-6
Hydrometer Test ...................................................
9-6 Discharge (Load) Test ..........................................
9-7
Test Preparation ................................................... 9-7
Test Procedure ..................................................... 9-7
Results Interpretation ............................................ 9-8
Storing Batteries ................................................... 9-8
Excessively Discharged Batteries ......................... 9-8
Replacing Batteries ............................................... 9-9
Removing Batteries ............................................... 9-9
Installing Batteries ................................................. 9-9
Battery Charger ..................................................... 9-9
Removal ................................................................ 9-9
Installation ............................................................. 9-9
SECTION 10 –TRACTION DRIVE SYSTEM
Traction Motor ....................................................... 10-1
Maintenance ......................................................... 10-1
External Inspection ............................................... 10-1
Internal Inspection ................................................. 10-1
Removal ................................................................ 10-1
Disassembly .......................................................... 10-2
Armature Inspection .............................................. 10-2
Armature Testing .................................................. 10-3
Brushes ................................................................. 10-3
Brush Springs ....................................................... 10-3
Bearing ................................................................. 10-5
Frame and Field Coils ........................................... 10-5
Field Coil Maintenance ......................................... 10-5
Inspection.............................................................. 10-5
Motor Reassembly ................................................ 10-5
Motor Installation ................................................... 10-6
Controller .............................................................. 10-7
ACEplus System ................................................... 10-7
Testing .................................................................. 10-7
Removing .............................................................. 10-7
Installing ............................................................... 10-7
Contactor/Solenoid ............................................... 10-8
Removing .............................................................. 10-8
Installing the Contactor ......................................... 10-8
CHANGE HISTORY- EX-21
DATE
DESCRIPTION
BY
12/9/13
Issued
TS

Service Manual
Section 1
Safety
OVERVIEW
Statements in this manual preceded by the words DANGER,
WARNING, CAUTION or NOTICE and words printed in bold
face are very important. We recommend you take special
notice of these items.
Danger indicates a hazardous situation which, if not
avoided, will result in death or serious injury.
Warning indicates a hazardous situation which, if not
avoided, could result in death or serious injury.
Caution indicates a hazardous situation which, if not
avoided, could result in minor or moderate injury.
NOTICE: Notices are messages not related to personal
injury. They will provide key information to prevent
property damage and to assure procedures are more
easily understood or implemented.
It is important to note that some warnings against the use of
specific service methods, which could damage the vehicle or
render it unsafe, are stated in this service manual. However,
please remember that these warnings are not all inclusive.
Since Columbia ParCar Corporation could not possibly know,
evaluate and advise servicing personnel of all possible ways in
which service might be performed or of the possible hazardous
Section 1 - Safety