Columbia ParCar Expediter EX21-24A Service Manual Download Page 45

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Section 6

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Front wheels, Fork & Steering

Figure 6

Summary of Contents for Expediter EX21-24A

Page 1: ...Columbia ParCar Corp SERVICE MANUAL Expediter EX21 24S EX21 24A EX21 48A 2013...

Page 2: ...sible 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...

Page 3: ...heel 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...

Page 4: ...ries 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...

Page 5: ...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 m...

Page 6: ...working on or near batteries 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 Eyes Flush...

Page 7: ...efer to pages 1 4 1 5 for locations NOTICE The modification of vehicles for use in other than its intended purpose is not recommended Any unauthorized modification may void your vehicle warranty This...

Page 8: ...Service Manual Section 2 General Information...

Page 9: ...form to requirements for Type E vehicles as described in O S H A Standard Section 1910 178 Powered Industrial Trucks and with all applicable portions of the American National Standard for Personnel an...

Page 10: ...and pleasant experience OPERATION NOTICE Each control should operate smoothly and easily without sticking or requiring excessive effort 1 Set the power key switch to the ON position 2 Set the directi...

Page 11: ...Auto adjusting mechanical rear drum foot parking brake Tires 4 8x8 LRB Recommend 50 psi 4 8x8 Foam Filled 4 0x8 Solid Non marking 4 8x8 Non marking Recommend 50 psi A POWER KEYSWITCH B DIRECTION SELEC...

Page 12: ...in each cell covers the top of cell plates See Section 4 11 if vehicle is equipped with a Single Point Battery Watering System Batteries are secure and free of corrosion All terminals and connections...

Page 13: ...Section 2 General Information...

Page 14: ...frequency of service Perform only those maintenance instructions described in this manual If major repairs are needed contact the local Columbia dealer for assistance Columbia dealers have the technic...

Page 15: ...annual2 50 Hours Annual2 Body Seat Frame Visually inspect for damage or tears X Hardware Tighten as needed X Vehicle Undercarrage Wash as needed X Clean Body Seat Wash as needed X Warning Operating La...

Page 16: ...wear and damage x Pressure See page 2 2 recommendations x Damaged rims x Front wheel alignment Check adjust as needed x Wheels Check lug nuts x Wheel bearing repack replace as needed x Check axle nut...

Page 17: ...rial Cracking splitting or melting of seat materials may occur If seat material becomes torn or split it should be replaced LIFTING INSTRUCTIONS Use extreme caution lifting or working around lifted ve...

Page 18: ...rneath frame 2 Place jack stands under frame at right and left sides to allow access under the vehicle 3 When work is completed place floor jack under rear axle housing lift the vehicle and remove the...

Page 19: ...3 5 Section 3 Maintenance 2 The specific gravity of the electrolyte should be checked every 6 to 8 weeks and charge as necessary to maintain 1 250 to 1 270 specific gravity...

Page 20: ...l Return the vehicle to its regular service Place the vehicle back into its regular watering schedule waiting at least 1 week until next watering 3 Check tire pressure and readjust if necessary 4 Perf...

Page 21: ...the following Torque Table as a general guide in determining proper torque When a metric equivalent is not listed use the Conversion Factors Chart to convert to metric values 3 6 Conversion Factors Ch...

Page 22: ...h Measurements inch mm 25 4 millimeter in 0 0394 foot m 0 3048 meter ft 3 281 miles kilometers 1 6 kilometers miles 0 621 Liquid Volume Measurements fluid ounces milliliters 29 57 milliliters fluid ou...

Page 23: ...ody or other parts open wire insulation or wire connections or discolored parts of the vehicle indicating heat or chemical presence Record the VIN This number is necessary to obtain technical help or...

Page 24: ...m be changed together to ensure the batteries are the same brand vintage and service life Test each battery cell with a battery hydrometer Any battery or battery cell that tests low should be fully ch...

Page 25: ...to Neutral slowly press the accelerator pedal The Accelerator Push value should rise in value from 0 100 smoothly as you press the pedal Figure 4 4 If the value does not change the controller is not r...

Page 26: ...verse Switch item and value If the switch fails to close in either direction check the switch with a VOM and the wiring back to the controller Pin 2 for Forward and Pin 3 for Reverse 5 Check the Seat...

Page 27: ...Section 4 Troubleshooting Figure 4 7...

Page 28: ...5 CL when the operator seat is occupied If the switch fails to close check the wiring from the B post of the controller to the seat switch test the seat switch with a VOM and check the wiring back to...

Page 29: ...discharged or damaged batteries or poor connections VEHICLE DRIVES IN FORWARD OR REVERSE ONLY Perform step 4 in Troubleshooting with Handheld Calibrator Figure 4 8 VEHICLE DRIVES BUT OPERATION IS JERK...

Page 30: ...not open with pedal up Ensure Pedal returns to 0 and microswitch is functioning properly 11 19 07 Repair or replace failed connection or component Controller pins are cross shorted Check wire harness...

Page 31: ...er Temperature cut out Review application and allow vehicle to cool 1 13 01 18 01 Contact Tech Support Current Cut Back Review application and allow vehicle to cool 3 13 01 18 01 Contact Tech Support...

Page 32: ...led Open wiring or failed connection Check wiring and connections Bulb burnt out Replace bulb Failed power key switch Test and replace contactor as necessary BRAKES Slow or Incomplete Release of Brake...

Page 33: ...akes the brake pedal springs and brake linkage to operate the brakes These brakes are self adjusting and should not require adjustment if shoe to drum clearance is within normal limits When brakes are...

Page 34: ...6 mm brake shoes must be replaced See Mechanical Rear Drum Brake Disassembly 4 Inspect for oil or grease contamination Replace brake shoes that are contaminated See Mechanical Rear Drum Brake Disasse...

Page 35: ...Section 5 Accelerator Brake System Figure 5 1 Figure 5 2...

Page 36: ...hoes may not be equal in length The shoe with the shorter lining should be installed on the brake assembly side closest to the front of the vehicle Shoe with longer lining installs to the rear 3 See F...

Page 37: ...ation should be confirmed before adjustments are made to cables and mechanical linkage Check that corrosion has not caused excessive resistance in the operation of the brake cables If corrosion is pre...

Page 38: ...parking brake set the vehicle should not roll on a steep incline or hill 5 With the gap properly set if the vehicle does move on when performing steps 4 5 perform the Mechanical Brake Linkage Adjustme...

Page 39: ...teering Always turn Power keyswitch to OFF Directional knob to Neutral remove Power keyswitch block tires and disconnect the battery negative cable before performing any vehicle service to avoid accid...

Page 40: ...ith suspension fork See Figure 6 1 Remove lug nuts and wheel assembly from the hub Remove the hub components shown in Figure 6 1 3 Wheel Model with non suspension fork See Figure 6 2 Remove the screw...

Page 41: ...wheel and place in fork Attach with screw washer and jam nut Tighten until resistance is felt 3 4 Wheel Models See Figure 6 3 Install bearing seal and inner bearing hub bearing washer and axle nut Ti...

Page 42: ...it with jack stands positioned under main frame tubes See Section 3 Maintenance Lifting Instructions On 3 wheel models use a soft mallet to tap the steering shaft and front fork assembly free of the...

Page 43: ...ng shaft and bushing INSTALLING STEERING WHEEL 1 Make sure wheels are pointed straight ahead 2 Apply Anti Seize to steering shaft Install steering wheel centered on splined shaft 3 Install steering wh...

Page 44: ...Section 6 Front wheels Fork Steering 6 Install steering column guard...

Page 45: ...Section 6 Front wheels Fork Steering Figure 6 5...

Page 46: ...Section 6 Front wheels Fork Steering 6 4...

Page 47: ...nts if worn Figure 6 7 INSTALLING 1 Install hex head screws nuts fork half clamps and suspension mounts to fork assembly 2 Install hex head screws washers locknuts and brackets to suspension mounts 3...

Page 48: ...tie rod end is right hand thread For long tie rod disconnect tie rod end from right hand spindle Take note that tie rod end is left hand thread Disconnect tie rod end from left hand spindle Take note...

Page 49: ...emove screw and jamnut securing trunnion to axle support 5 Remove kingpins and jamnuts securing steering spindles to trunnion 6 Replace bushings 7 Install steering spindles to trunnion with kingpins a...

Page 50: ...Section 6 Front wheels Fork Steering Service Manual Section 7 Rear Wheels Rear Suspension Axle Assembly...

Page 51: ...Section 6 Front wheels Fork Steering 2013 EX 21 Service Manual...

Page 52: ...studs 2 Tighten four lug nuts by hand and wrench until snug using a criss cross pattern 3 Lower the vehicle to the ground and torque the lug nuts to 65 ft lbs using the same criss crossing pattern TIR...

Page 53: ...Section 7 Rear Wheels Rear Suspension Axle Assembly REAR AXLE ASSEMBLY 4 Remove rear shock absorbers and springs as described Figure 7 1...

Page 54: ...ent of parts must be done with great care in a clean environment Before attempting to perform any axle service read and understand all the procedures in this section Handle all gears with extreme care...

Page 55: ...s and bearing bores Remove all residual gasket material from sealing surfaces Use soft clean lint free towels to dry components before cleaning Parts should be cleaned with emulsion cleaners or petrol...

Page 56: ...Section 7 Rear Wheels Rear Suspension Axle Assembly Figure 7 4...

Page 57: ...Section 7 Rear Wheels Rear Suspension Axle Assembly Figure 7 6...

Page 58: ...and disassemble the other shaft 7 Remove ten cover screws 20 8 Position the axle housing 1 over a drain pan Using a putty knife separate the cover plate from the housing Figure 7 9 Use care to not dam...

Page 59: ...differential bearings 8 from each side of the differential case See Figure 7 12 11 Remove four bolts 6 and nuts 7 from the final drive output gear 5 Remove gear from differential case Use care not to...

Page 60: ...Section 7 Rear Wheels Rear Suspension Axle Assembly...

Page 61: ...may be required See side Figure 7 18 17 Remove oil seal 30 not shown and snap ring 16 from 12 Punch or drill a 1 8 diameter hole near the center of each intermediate cup plug 17 Insert a suitably size...

Page 62: ...nto bearing bore of input shaft 12 NOTICE Input shaft assembly must be supported by hand as not to damage gear teeth Use care if using a hammer to coax shaft and gear into correct position Use care if...

Page 63: ...TICE Intermediate shaft assembly must be supported by hand as not to damage gear teeth Use care if using a hammer to coax shaft and gear into correct position 8 After flanged side bearing is seated pa...

Page 64: ...olts 20 Torque bolts to 16 24 ft lbs 21 5 32 5 Nm 15 Install new intermediate cup plug 17 to both sides of housing 1 Use Loctite Safety Solvent 75559 to clean bores then apply Loctite RC 609 to housin...

Page 65: ...side 8 Install spacers and wheel assemblies as described previously in this section 9 Drive the vehicle and test axle operation Figure 7 31 REAR AXLE DIFFERENTIAL OIL CHANGING DIFFERENTIAL OIL Differe...

Page 66: ...ver and drain oil into drain pan 3 Clean carrier cover with lint free rag 4 Place a small bead of RTV non acidic silicone sealant to flange of cover plate 18 Sealant should be applied to inside of cov...

Page 67: ...Section 7 Rear Wheels Rear Suspension Axle Assembly...

Page 68: ...power key to off directional keyswitch to neutral remove power key block tires and disconnect the battery negative cable before performing any vehicle service to avoid accidental startup of vehicle an...

Page 69: ...secure with retaining bracket nuts and washers Reconnect wires to BDI HOUR METER Not Shown 1 Remove wires from back and squeeze the tabs on the retaining bracket Remove it from front of console 2 Pos...

Page 70: ......

Page 71: ...t back in the upright position lift seat back up and forward and engage the retaining pins into the mounting plate slots while pushing down on the seat back To remove seat back remove the screws washe...

Page 72: ...Figure 8 6 8 2...

Page 73: ...pecifically designed to handle this type of service Proper performance of your Columbia Vehicle can only be obtained from specified deep cycle electric vehicle batteries SAFETY INFORMATION All batteri...

Page 74: ...ush battery cable and wire connections clean using soft brass wire brush 3 Replace battery cable terminals that are damaged or corroded 4 Keep the batteries clean fully charged properly secured and te...

Page 75: ...he other having a female coupler and a rubber squeeze bulb NOTICE To avoid overfilling of the Single Point Watering System do not operate this system on brand new batteries New batteries should be in...

Page 76: ...he factory for different types of batteries as well as different brands and capacities of batteries Refer to Battery Brand Algorithms for Charger Programming See Table 1 The lead acid storage battery...

Page 77: ...xide DF06240 200 300Ah gel 21 Exide Flooded 210 Flooded Exide 3ET200 FF06255 185PZB210 Exide200 Ah 300 Ah Flooded 26 Deka 8GGC2 Gel 180 Gel Deka 8GGC2 Deka 150 230Ah gel 35 Concorde 200Ah AGM 200 AGM...

Page 78: ...ximately 80 state of charge The 80 LED remains on as the last 20 of charge is returned to the batteries in the second phase constant voltage phase NOTICE You can terminate charging at this point if ne...

Page 79: ...cement and return CHARGING PROCEDURE 1 Check electrolyte level in all cells Add distilled water as necessary to cover tops of plates Do not over fill as electrolyte expands during charging 2 Be sure c...

Page 80: ...even for short runs prior to Discharge Load Test Electrolyte level must be correct in all cells TEST PROCEDURE Discharge Load Test must be performed in well ventilated area 1 Connect tester leads to b...

Page 81: ...posit as a white crystalline mass Subsequent charging may convert these deposits into stringy metallic lead which may short the positive and negative plates through the areas affected These small shor...

Page 82: ...ires to connector on red wire 14 on the interlock circuit The black and white wires at battery B are terminated in a thermistor Take extra care when handling the thermistor 1 Disconnect 4 wires in cha...

Page 83: ...Section 9 Battery and Battery Charger...

Page 84: ...Service Manual Section 10 Traction Drive System TRACTION MOTOR MAINTENANCE...

Page 85: ...able commutator and or brush conditions internal repairs can be performed before major component damage or failure occurs Brush and commutator inspection can be accomplished by removing the motor head...

Page 86: ...inal assemblies are removed See exploded view Figure 10 9 8 Remove bearing retainer snap ring shown in Figure 105 Carefully press out the bearing from motor head Replace the bearing 9 Remove all the b...

Page 87: ...ored brush leads and brush springs Check brush box for physical damage Make sure brush holders are not loose on the brush box assembly See Figure 10 9 Check brush for correct clearance and freedom of...

Page 88: ...l spring scale as shown 3 Pull spring scale on a line directly opposite the spring force When paper strip can be moved freely read spring tension on scale Brush spring tension New 64 ounces 1792 grams...

Page 89: ...Section 10 Traction Drive System Figure 10 10...

Page 90: ...Section 10 Traction Drive System...

Page 91: ...rush holder into motor head as shown in Figure 10 16 Make sure that the terminals for the brushes are loose and free Figure 10 14 4 Install insulators and brush leads into motor head See Figure 10 17...

Page 92: ...action motor double checking wiring diagram to motor cable installation to 5 Pull back each brush in it s holder allowing the spring to rest against the side of each brush This will hold each brush in...

Page 93: ...flashing count the number the flashes in each sequence Refer to Section 4 Troubleshooting for controller flash troubleshooting info and for info on testing controller with Sevcontrol Calibrator or PC...

Page 94: ...n circuit between the large terminals preventing current from passing through it Solenoids are mounted in vertical position Gravitational pull aids internal spring in returning to normal position REMO...

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