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

2-b
CHAPTER 2
GENERAL AND MAINTENANCE INFORMATION PAGE #
PERIODIC MAINTENANCE 2-14
Calendar Year Reference Chart 2-14
Maintenance Schedule Checklist 2-14
Gas Vehicles 2-16
Chassis Lubrication
Air Filtration
Engine Oil and Lubrication Service
Rear Axle Service
Accelerator and Governor Controls
Electric Vehicles 2-23
Batteries
Chassis Lubrication
Rear Axle Service
Bodies, Seats, & Components 2-26
Front Body Removal
Refinishing
Installation
Seats & Handrails
Bag Rack
Mid and Rear Bodies
Golf/Commercial (Fiberglass)
Industrial Rear Bodies (Steel Body)

2-1
Model Vin Prefix Name Use Type Power System
P4G 8E Eagle Golf Gas 4 Cycle 9 HP Briggs & Stratton
P4E 3E Eagle Golf Battery 36/48 Volt System
P5E E Eagle Golf Battery 36/48 Volt System
FG 8F Foursome Golf Gas 4 Cycle 9 HP Briggs & Stratton
FE 4F Foursome Golf Battery 36/48 Volt System
GU4 8U Utilitruck Utility Gas 4 Cycle 9 HP Briggs & Stratton
EU4 4E Utilitruck Utility Battery 36/48 Volt System
GUXB 8X Utilitruck Utility Gas 4 Cycle 9 HP Briggs & Stratton
Extended Bed
EUXB 4X Utilitruck Utility Battery 36/48 Volt System
Extended Bed
GU2400 9J Utilitruck Utility Gas 4 Cycle 13 HP Briggs & Stratton
EU2400 5J Utilitruck Utility Battery 36/48 Volt System
GU2400XB 9N Utilitruck Utility Gas 4 Cycle 13 HP Briggs & Stratton
Extended Bed
EU2400XB 5N Utilitruck Utility Battery 36/48 Volt System
Extended Bed
GD4 8D Utilidump Utility/Dump Gas 4 Cycle 9/13 HP Briggs &Stratton
ED4 4D Utilidump Utility/Dump Battery 36/48 Volt System
C6G 8S Shuttle People Mover Gas 4 Cycle 9 HP Briggs & Stratton
C6E 4S Shuttle People Mover Battery 36/48 Volt System
C10G 9H Tram People Mover Gas 4 Cycle 13 HP Briggs & Stratton
C10E 5H Tram People Mover Battery 36/48 Volt System
911G 8Z Ambulance Medical Transport Gas 4 Cycle 9 HP Briggs & Stratton
911E 4Z Ambulance Medical Transport Battery 36/48 Volt System
VEHICLE AND MODEL INFORMATION

2-2
The Vehicle Identification Number (VIN) of each vehicle, describes many different facts or features of the vehicle. Refer
to the VIN Chart below to determine unique features of your vehicle.
Vehicle Identification Number (VIN) Matrix
VIN, Four Character System Sequential Serial # Suffix (when used)
1st Character 2nd Character 3rd & 4th Characters 5 Numeric 1 Alpha/1 Numeric
Power System Model Code Factory Characters
Designation Modifications/Options
to Standard Vehicle
3=PowerMaster C=Classic A=36 volt high speed Example=12345 Decade
System motor D=1900
E=2000
4=Std XP D=Utilidump D=48 volt Power System Year
Power System 8 6V batteries 8=1998
9=1999
0=2000
1=2001
5=XP+ E=Eagle E=48 volt Power System
Power System 6 8V batteries
8=9 HP 4 cycle F=Foursome S=Special Product
engine Modification
9=13 HP 4 cycle H=Tram W=Front wheel hydraulic
engine disc brakes
J=Utilitruck X=4 wheel hydraulic disc
2400 brakes
N=Utilitruck Y=Rear wheel hydraulic
2400XB disc brakes
S=Shuttle Z=Custom Carts model
U=Utilitruck
X=UtilitruckXB
Z=Ambulance
SP, when used
indicates this is a
Special Vehicle having
been significantly
modified from model
indicated by model pre-
fix.It is critical when
ordering parts for any
vehicle that you give
the entire vehicle VIN
to Columbia ParCar
customer service to
ensure correct service
parts are ordered and
supplied.
VIN Plate
Location
Note: ALWAYS, provide the complete VIN when contacting your Dealer for technical assistance or maintenance and
repair parts. For golf and commercial vehicles, the VIN number is printed on a white label located in the upper right
inside floorboard or stamped on a metal name plate affixed to the rear fender (under the rear body). On Industrial mod-
els, the VIN name plate is located at the front right corner of the rear body.
1996~1999 Eagle
2000 Eagle & Shuttle
1996~1999 Shuttle
Utility/Tram/Ambulance

2-3
General Vehicle Specifications
Item Specifications Vehicle
P4G P4E FG FE GU4 EU4 GUXB EUXB
Power Source
Engine 9 HP 4 cycle, Single cylinder, fan air * * * *
cooled, OHV Briggs & Stratton
13 HP 4 cycle, Single cylinder, fan air
cooled, OHV Briggs & Stratton
Motor 36 Volt, DC series wound, Reversible, ****
NEMA Class H insulation, 3.2 HP
@2800 RPM
Drive Direct coupled to helical geared ****
differential
Speed Control Infinitely variable, solid state ****
maintenance free, 275 AMP
Transmission Fully automatic torque sensing * * * *
variable speed with overdrive
Transaxle112.44:1 Helical gear reduction with * * *
integral differential
13.32:1 Helical gear reduction with * * * *
integral differential
13.25:1 Helical gear reduction with *
integral differential, Heavy duty
Electrical Solid state voltage regulator, 12 volt * * * *
heavy duty battery
Batteries236 Volt: Six 6-volt, Heavy duty, 220Ah, ****
deep cycle
48 Volt: Eight 6-volt, Heavy duty, ****
220 Ah, deep cycle
Charger Lestronic II 36/48 Volt, 25 AMP PPBB
(Portable) or 30 AMP (Built-in)
Directional Dash mounted safety directional ****
Control keyswitch, forward, reverse and off
Dash mounted safety directional shift * * * *
control, forward, reverse and off
Air Intake Micro-clean primary and safety element * * * *
Brakes, Steering and Suspension
Brakes3Auto adjusting mechanical drum rear, * *******
Automatic release parking brake
Hydraulic drum brakes on rear, hand
operated parking brake
Steering Automatic adjusting, speed balanced, * *******
Automotive rack and pinion
Suspension Front-multi-leaf spring with dual shock
absorbers * *******
Rear-Independent dual coil springs with
dual shock absorbers
Body and Chassis
Tires4G=Golf, 18x8.5-8 Classic St (Std) GGGGIIII
I=Industrial 5.70x8 Industrial Service
(Std)
Frame Mig-welded tubular steel, electrostatic * *******
powder coated
Capacities
Fuel tank 7 U.S. Gallon Capacity5****
Capacity Total number of occupants and cargo 2 2 4 4 2 2 2 2
not to exceed _lbs. 750 750 1100 1100 1200 1100 1200 1100
lbs. lbs. lbs. lbs. lbs. lbs. lbs. lbs.

2-4
General Vehicle Specifications (Continued)
Item Specifications Vehicle
GU EU GU EU GD4 ED4 C6G C6E
2400 2400 2400XB 2400XB
Power Source
Engine 9 HP 4 cycle, Single cylinder, fan air *
cooled, OHV Briggs & Stratton
13 HP 4 cycle, Single cylinder, fan air * * *
cooled, OHV Briggs & Stratton
Motor 36 Volt, DC series wound, Reversible, ****
NEMA Class H insulation, 3.2 HP
@2800 RPM
Drive Direct coupled to helical geared ****
differential
Speed Control Infinitely variable, solid state ****
maintenance free, 275 AMP
Transmission Fully automatic torque sensing ****
variable speed with overdrive
Transaxle112.44:1 Helical gear reduction with
integral differential
13.32:1 Helical gear reduction with * *****
integral differential
13.25:1 Helical gear reduction with * *
integral differential, Heavy duty
Electrical Solid state voltage regulator, 12 volt ****
heavy duty battery
Batteries236 Volt: Six 6-volt, Heavy duty, 220Ah, ****
deep cycle
48 Volt: Eight 6-volt, Heavy duty,
220 Ah, deep cycle
Charger Lestronic II 36/48 Volt, 25 AMP BBPP
(Portable) or 30 AMP (Built-in)
Directional Dash mounted safety directional ****
Control keyswitch, forward, reverse and off
Dash mounted safety directional shift ****
control, forward, reverse and off
Air Intake Micro-clean primary and safety element ****
Brakes, Steering and Suspension
Brakes3Auto adjusting mechanical drum rear, ****
Automatic release parking brake
Hydraulic drum brakes on rear, hand ****
operated parking brake
Steering Automatic adjusting, speed balanced, ********
Automotive rack and pinion
Suspension Front-multi-leaf spring with dual shock ********
absorbers
Rear-Independent dual coil springs with
dual shock absorbers
Body and Chassis
Tires4G=Golf, 18x8.5-8 Classic St (Std) IIIIIIII
I=Industrial 5.70x8 Industrial Service
(Std)
Frame Mig-welded tubular steel, electrostatic ********
powder coated
Capacities5
Fuel tank 7 U.S. Gallon Capacity ****
Capacity Total number of occupants and cargo 2 2 2 2 2 2 4 4
not to exceed _lbs. 2400 2400 2400 2400 1200 1100 1200 1100
lbs. lbs. lbs. lbs. lbs. lbs. lbs. lbs.

2-5
General Vehicle Specifications (cont.)
Item Specifications Vehicle
C10G C10E 911G 911E
Power Source
Engine 9 HP 4 cycle, Single cylinder, fan air *
cooled, OHV Briggs & Stratton
13 HP 4 cycle, Single cylinder, fan air *
cooled, OHV Briggs & Stratton
Motor 36 Volt, DC series wound, Reversible, * *
NEMA Class H insulation, 3.2 HP
@2800 RPM
Drive Direct coupled to helical geared * *
differential
Speed Control Infinitely variable, solid state * *
maintenance free, 275 AMP
Transmission Fully automatic torque sensing * *
variable speed with overdrive
Transaxle112.44:1 Helical gear reduction with
integral differential
13.32:1 Helical gear reduction with *
integral differential
13.25:1 Helical gear reduction with *
integral differential, Heavy duty
Electrical Solid state voltage regulator, 12 volt * *
heavy duty battery
Batteries236 Volt: Six 6-volt, Heavy duty, 220Ah, * *
deep cycle
48 Volt: Eight 6-volt, Heavy duty,
220 Ah, deep cycle
Charger Lestronic II 36/48 Volt, 25 AMP B B
(Portable) or 30 AMP (Built-in)
Directional Dash mounted safety directional * *
Control keyswitch, forward, reverse and off
Dash mounted safety directional shift * *
control, forward, reverse and off
Air Intake Micro-clean primary and safety element * *
Brakes, Steering and Suspension
Brakes3Auto adjusting mechanical drum rear, * *
Automatic release parking brake
Hydraulic drum brakes on rear, hand * *
operated parking brake
Steering Automatic adjusting, speed balanced, ****
Automotive rack and pinion
Suspension Front-multi-leaf spring with dual shock
absorbers ****
Rear-Independent dual coil springs with
dual shock absorbers
Body and Chassis
Tires4G=Golf, 18x8.5-8 Classic St (Std) IIII
I=Industrial 5.70x8 Industrial Service
(Std)
Frame Mig-welded tubular steel, electrostatic ****
powder coated
Capacities5
Fuel tank 7 U.S. Gallon Capacity * *
Capacity Total number of occupants and cargo 10 10 3 3
not to exceed _lbs. 2000 2000 1200 1100
lbs. lbs. lbs. lbs.

Notes from General Vehicle Specifications:
1Optional transaxles may be used for different
applications.
2Six, 8-volt batteries may be used for 48-volt system.
3Other brake options are available depending on
application. Contact your Columbia ParCar Dealer.
4Other tire styles and sizes are available for different
applications.
5For a full list of dimensions and capacities, refer to your
vehicle owner’s manual.
Columbia ParCar golf cars are designed to conform
to ANSI standards and OSHA standards.
Columbia Utilitrucks are designed to conform to
ANSI B56.8 and OSHA standards.
Columbia ParCar Corp. reserves the right to change
specifications, equipment or designs at any time
without notice and without incurring obligations.
Safety Committee
If the Gasoline or Electric, Golf or Industrial Vehicles are
to be operated by renters or company employees, we
recommend that a safety committee be appointed. The
primary concern of this committee should be the safe
operation of the vehicles.
Subjects which must be considered include, but not limit-
ed to, the following:
a. Define where the vehicles should and should not
be driven and utilized.
b. Ensure all proper warnings as to driving hazards
are properly displayed and visible.
c. Safety signage concerning hills, turns, blind
crossings or intersections is highly
recommended.
d. Enforcement of safe driving and operating rules.
e. Provide driver training for first time operators,
and review safe operating recommendations
regularly.
f. Maintain vehicles in a safe operating condition.
Maintain a schedule for daily, weekly, and
monthly vehicle inspections.
g. Who, when and how should pre-operation
inspections be conducted.
h. Define who should and who should not drive the
vehicles.
i. What to do should an unsafe condition or
operating problem be discovered.
Note: Refer to OSHA regulations for additional require-
ments regarding operator training.
These basic rules of operation, combined with courtesy
and common sense, will help make driving your
Columbia ParCar vehicle a safe and pleasant experi-
ence. The safety committee should be made up of man-
agers and/or supervisors in charge or responsible for the
operation and maintenance of the vehicles.
Controls and Operation
Location of Controls
Figure 1 shows location of your vehicle’s controls.
Simple controls make it easy to operate a Columbia
ParCar Golf or Columbia Industrial Vehicle. To drive,
move the Safety Directional Keyswitch/Shift Control to
desired position and depress accelerator with right foot.
Depress brake pedal to slow or stop vehicle.
Warning: On electric vehicles, be sure safety
directional keyswitch is in desired direction of
travel before depressing accelerator. On gaso-
line vehicles, be sure the safety directional shift
control is in the desired direction of travel
before depressing accelerator.
Caution:
Golf Cars:
* Golf cars are to be used for golf play only.
* It is hazardous to use golf cars anywhere
other than on designated car paths and car
areas.
* This vehicle is designed for transporting no
more than (2) golfers and their equipment.
The only exception is the foursome vehicle
designed to handle four (4) golfers and their
equipment.
* Never exceed the rated load capacity or vehi-
cle stability, reliability and control will be
reduced.
Industrial Vehicles:
* Industrial vehicles are designed to transport
no more than two (2) people unless adequate
provisions have been factory installed to
accommodate additional passengers.
* Never exceed the rated load capacity or vehi-
cle stability, reliability and control will be
reduced. See vehicle identification plate for
capacities.
* Before operating vehicle, ALWAYS, distribute
and secure loads.
2-6

Pre-Operations Inspections
Your Columbia ParCar vehicle has been inspected and
adjusted to factory specifications before delivery. Upon
receipt of vehicle, make a predelivery inspection of the
vehicle. Also, before using the vehicle, there are checks
that must be performed to ensure that it is in safe proper
working order.
Warning: Only trained maintenance profession-
als should service or repair this vehicle.
Persons doing even simple repairs or service
should have working knowledge and experience
in general electrical and mechanical repair.
Follow all procedures and observe all warnings
stated in this manual. Use caution and common
sense.
Note: Controls should operated smoothly and easily
without sticking or requiring undue effort. The service
manual contains maintenance procedures necessary to
perform maintenance on your vehicle. Maintenance
and/or repair to fuel metering systems, air induction sys-
tems, ignition system, exhaust system (including connec-
tors and assembling) could affect emissions controls on
the engine. Contact your Columbia ParCar Dealer or
Columbia ParCar at [phone] for instruction
and/or recommendations before proceeding.
2-7
Figure 1- Location of Controls
Choke
Key Switch
Warning Label
Light Switch (optional)
Horn (optional except on
industrial vehicles)
Operating
Instructions
Directional
Control Lever
Turn Signal
Lever
(optional)
Accelerator
Pedal
Gasoline
Warning Label
Operating Instructions
Safety Directional Keyswitch
State of Charge Meter
(optional - Golf Cars, standard on
Industrial/Commercial Vehicles)
Parking Brake
Pedal
Brake Pedal
Hand Operated
Park Brake (stan-
dard on hydraulic
brake models) Electric

2-8
What to do if you find a problem:
1. If vehicle has just been delivered, report any physical
damage or missing items to the Shipping Company
and your local Columbia ParCar Dealer.
* Look for body damage, jagged edges etc. that
may cause personal injury.
* Check for damaged or leaking batteries.
* Verify bumpers are not bent out or protruding and
are attached properly.
2. Daily, before operation, assess what affect the prob-
lem has on the safe operation of the vehicle.
* If the safe operation of the vehicle is affected,
remove the vehicle from service until the problem
has been corrected. Report the problem to the
individual(s) responsible for correction and/or
repair.
* If the safe operation of the vehicle is not affected,
record the problem and report it to the individual(s)
responsible for correction and/or repair.
3. Report any service item problems to the individual(s)
responsible for correction and/or repair or contact your
local Columbia ParCar Dealer for service.
* Refer to Pre-Operations Checklist.
Danger: If any problems are found, DO NOT
operate vehicle until repairs are made. Failure
to make necessary repairs could result in fire,
severe personal injury, property damage or
death. Consult your local Columbia ParCar
Dealer for professional service.
Pre-Operations Check List
Service Item Service Method/Check Manual Reference
Vehicle Body Visually, check for damaged and loose See note.
hardware.
Steering and Linkages Test drive, check for free movement See note.
and proper operation.
Brake Operation Test drive, check free travel and Refer to owner’s manual for
braking action. specifications, Section 5.1.
Parking Brake Test drive, check latching and proper Refer to owner’s manual for
release. specifications, Section 5.1.
Warning Labels Visually, inspect all labels for Verify labels are in place and
readability or missing. readable.
Tires Visually, check for wear or damage. Refer to owner’s manual for
specifications, Section 5.2.4.c.
Engine Test drive, check for proper operation. See note.
Accelerator/Governor Linkage Test drive, check for free movement. See note.
Reverse Warning Buzzer Test drive, check for proper operation. Verify an audible sound heard.
Air Intake Screen Visually, check for clogged screen. Refer to owner’s manual for
specifications, Section 5.2.4.a.
Fuel System Visually, check tank, lines, pump and See note.
carburetor for fuel leakage.
Charger Plug and Receptacle Check for damage and snug fit. Refer to owner’s manual for
specifications, Section 5.3.1.a.
Batteries Charge. Refer to owner’s manual for
specifications, Section 5.3.1.a.

2-9
Torques and Metric Conversion Factors
Individual component torques and metric equivalents are listed where the maintenance is performed throughout this
manual. When a specific fastener torque is not specified, use this Torque Table as a general guide in determining the
proper torque. When a metric equivalent is not listed, use the conversion factor table to convert the metric values.
Torque Table
Torque to the value in this table unless specified otherwise.
Fine or
course
thread
fastener
Cap
Screw
Cap
Screw
Cap
Screw
Cap
Screw
Cap
Screw
Cap
Screw
Cap
Screw
Cap
Screw
Cap
Screw
Grade
Designation
S.A.E. 2
A.S.T.M
A-307
Steel
S.A.E. 3
Steel
S.A.E. 5
A.S.T.M
A-499
Steel
A.S.T.M
A-354BB
Steel
A.S.T.M
A-325
A.S.T.M
A-354-BC
Steel
S.A.E. 6
Steel
S.A.E. 7
Steel
S.A.E. 8
Steel
Tensile
Strength
Minimum
64,000
P.S.I.
100,000
P.S.I.
105,000
P.S.I.
125,000
P.S.I.
133,000
P.S.I.
150,000
P.S.I.
Material
Low Carbon
Steel
Medium
Carbon Steel
Medium
Carbon Steel
Or Low Alloy
Heat Treated
Low Alloy or
Med. Carbon
Steel
Quenched
Tempered
Med. Carbon
Steel
Quenched
Tempered
Med. Carbon
Alloy
Quenched
Tempered Roll
Threaded
Med. Carbon
Alloy
Quenched
Tempered
Screw, Stud or bolt shank size or diameter
Torque figures are in ft. lbs.
1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1
6 11 19 30 45 66 90 150 202 300
9 17 30 47 69 103 145 234 372 551
9 18 31 50 75 110 150 250 378 583
100 200 355 525 790
11 20 34 54 81 119 167 269 427 644
12.5 24 43 69 106 150 209 350 550 825
13 28 46 75 115 165 225 370 591 893