Columbia ParCar P4G User manual

Service Manual
PART NO. 99496-96
3-00
Gasoline and Electric
Golf and Industrial
Four Wheel Vehicles

350 N. Dewey
P.O. Box 30
Reedsburg, WI 53959
Phone [phone]
Toll-Free (800) 222-GOLF
Fax [phone]
Web www.parcar.com
E-Mail [e-mail]

FOREWORD
This service manual has been prepared with two purposes in mind. First, it will introduce the trained maintenance pro-
fessional to the latest field-tested and factory-approved major repair methods. Secondly, it will acquaint the reader with
the construction of Columbia ParCar vehicles and assist him/her in performing basic maintenance and repair. We sin-
cerely believe that this manual will make your association with Columbia ParCar vehicles more pleasant and profitable.
In addition to the information given in this Service Manual, Service Bulletins are issued to Columbia ParCar Dealers,
from time to time, 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 Columbia ParCar vehicles and to protect the vehicles from possible damage
resulting from improper service or maintenance, the procedures followed in this manual should always be followed
exactly as outlined. Execution of the procedures and trouble-shooting tips as outlined will ensure the best possible serv-
ice from the vehicle(s). To reduce the chance of personal injury and/or property damage, carefully observe NOTES,
CAUTIONS, WARNINGS and DANGER recommendations throughout this manual. See Chapter 1 for additional details.
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 front of each section.
Model Identification
Always, give the full vehicle identification number when ordering parts or making inquiries about your Columbia ParCar
vehicle.
Use of the full and complete vehicle identification number (VIN) information will assure your dealer or service provider is
supplying you with the correct parts for your vehicle. See Chapter 2 for vehicle identification information.
Use Genuine Replacement Parts
Warning: When replacement parts are required, use only genuine Columbia parts or parts with equivalent
characteristics including type, strength and material. Failure to do so may result in product malfunction
and possible injury to the operator and/or passenger.
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.
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.

TABLE OF CONTENTS CHAPTER #
Safety 1
General Information 2
Steering & Suspension 3
Brake Systems 4
Torque Converter/Transmission System 5
Directional Shifting Control (Gas Vehicles) 6
& Final Drive Axles
Briggs & Stratton Engines 7
& Exhaust System
Electrical System & Components 8

1-a
CHAPTER 1
SAFETY PAGE #
Overview 1-1
All Vehicles 1-1
Gasoline Vehicles 1-2
Electric Vehicles 1-4

1-1
OVERVIEW
Statements in this manual preceded by the words NOTE, CAUTION, WARNING or DANGER and printed in bold face
are very important. We recommend you take special notice of these items.
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 inclu-
sive. Since Columbia ParCar could not possibly know, evaluate and advise servicing personnel of all possible ways in
which service might be done or of the possible hazardous consequences of each way, we have not undertaken any such
broad evaluation. Accordingly, anyone who uses a service procedure or tool which is not recommended by Columbia
ParCar must first thoroughly satisfy himself that neither his nor the operator's safety will be jeopardized by the service
methods selected.
Danger: Danger indicates an immediate hazard that will result in severe personal injury or death.
Warning: Warnings will indicate an immediate hazard, which could result in severe personal injury.
Caution: Cautions indicate hazards or unsafe practices, which could result in minor personal injury,
damage to the vehicle or to other property.
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.
Notes, Cautions, Warnings And Dangers
ALL VEHICLES
Danger Any modifications or changes to the vehicle that affect the stability or increases vehicle
speed beyond factory specifications could result in severe personal injury or death.
Always, remove key and disconnect the battery(s) before servicing or repairing your
vehicle. See Battery, Chapter 8, for details.
All batteries used in gas or electric vehicles can explode! Always, wear full-face shield
when working on or near batteries. Hydrogen fumes are a natural byproduct of charging
and discharging and are extremely explosive. Do not smoke. Keep sparks and flames
away from batteries. Battery charging should only be done in a well-ventilated area. See
Batteries, Chapter 8, for details.
If any problems are found during scheduled maintenance or inspections, DO NOT
operate vehicle until repairs are made. Failure to make necessary repairs could result in
fire, property damage, severe personal injury, or death.

Notes, Cautions, Warnings And Dangers
1-2
ALL VEHICLES
Only trained maintenance professionals should repair or service this vehicle. Persons
Warning doing even simple repairs or service should have working knowledge and experience in
general electrical and mechanical repair. 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. Some of these service operations
require the use of tools specially designed for this purpose. These special tools should be
used when and as recommended.
Moving parts hazard! When operating any vehicle in a stationary position, avoid spinning
clutches, belts, and wheels which could snag clothing or cause severe injury to body parts.
A running vehicle must be worked on with the greatest care. Use caution and common
sense.
Working on Columbia ParCar vehicles without following proper procedures and using
proper lifting equipment may result in vehicle damage or personal injury. See Lifting
Instructions in Chapter 2 for detailed instructions.
Failure to maintain vehicle properly could result in decreased vehicle performance,
reliability or cause severe personal injury.
Always, wear safety glasses or approved eye protection while servicing vehicle. Wear a full
face shield when working with batteries.
Exceeding rated vehicle load capacities could result in possible severe injury or property
damage.
The modification of golf cars for use in other than golf play is not recommended.
Caution Cautions appear throughout this manual indicating possible hazards or unsafe
practices that may result in minor personal injury, damage to vehicles or property.
Note Notes appear throughout this manual to provide key information to assure procedures are
more easily understood or implemented.
GASOLINE-POWERED VEHICLES
Gasoline is extremely flammable and highly explosive under certain conditions. When
Danger refueling or servicing gasoline-powered vehicles, always, stop engine. Do not smoke, and
keep away from open flame or sparks.
DO NOT operate when the smell of gasoline is present or other explosive conditions exist
which could result in severe personal injury or death.
DO NOT operate vehicle in an enclosed area without proper ventilation. Engines produce
carbon monoxide, which is a colorless, odorless and deadly gas.
BATTERY - Is poisonous! Contains acid which causes severe burns! Avoid contact with skin,
eyes or clothing.

1-3
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.
Warning: Only trained maintenance professionals should repair or service this vehicle.
Persons doing even simple repairs or service should have working knowledge and
experience in general electrical and mechanical repair. Follow all procedures exactly
and observe all warnings stated in this manual. Use caution and common sense.
To avoid accidental starting of the vehicle, always, turn key switch OFF, remove key,
disconnect battery negative (-) cable and remove spark plug wire from spark plug prior to
servicing.
Hot engine and exhaust system! DO NOT attempt to service while hot. Failure to observe
this warning could result in severe burns.
DO NOT refuel indoors where area is not well-ventilated. Outdoor fueling is
recommended.
DO NOT store, spill or use gasoline near open flame or stoves, furnaces or water heaters
that use a pilot light, or device which causes a spark that could ignite a fire.
DO NOT fill fuel tank while engine is hot. Allow engine to cool for 2 minutes before
refueling. Store all fuels in properly marked containers.
DO NOT operate engine if gasoline is spilled. Push vehicle away from the spill and avoid
creating any possible ignition until the spill has evaporated or has been properly taken care
of.
Caution: Cautions appear throughout this manual indicating possible hazards or unsafe
practices that may result in minor personal injury, damage to vehicles or property.
Notes Notes appear throughout this manual to provide key information to assure procedures are
more easily understood or implemented.

1-4
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.
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 physical immediately.
- EYES: Flush with water for fifteen minutes. Call a physician immediately.
Only trained maintenance professionals should repair or service this vehicle. Persons
Warning doing even simple repairs or service should have working knowledge and experience in
general electrical and mechanical repair. Follow all procedures exactly and observe all
warnings stated in this manual. Use caution and common sense.
Always turn key switch to OFF, remove key, block tires and disconnect the battery negative
(-) cable on XP and XP Plus models before performing any vehicle service to avoid
accidental start-up of vehicle and possible injury.
To prevent accidental starting of the Power Master model, turn tow switch to tow position,
disconnect the battery positive cable (+), turn key to reverse position until warning buzzer
is silent.
HOT! - DO NOT attempt to service hot motor or resistors. Failure to observe this warning
could result in severe burns.
Caution Cautions appear throughout this manual indicating possible hazards or unsafe practices
that may result in minor personal injury, damage to vehicles or property.
Notes Notes appear throughout this manual to provide key information to assure procedures are
more easily understood or implemented.

2-a
CHAPTER 2
GENERAL AND MAINTENANCE INFORMATION PAGE #
Vehicle and Model Information 2-1
Vehicle Identification Number (VIN) Chart 2-2
Vehicle Specifications 2-3
Safety Committee 2-6
Pre-operation Inspections 2-7
Torques and Metric Conversion Factors 2-9
Torque Table
Metric Conversion Chart
Lifting Instructions 2-10
Hoist Lifts
Floor Jacks
Hydraulic Lifts
Jack Stands
Vehicle Storage 2-11
Gas Vehicles
Electric Vehicles
Towing & Transporting Vehicles 2-13