Columbia CR-10 Chariot, Service Manual

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Page 2: ...low you to perform the repair as easily and quickly as possible and reduce the incidence of misplaced tools and parts Columbia Industrial Commercial 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 ...

Page 3: ...ering Handle Bars 2 4 2 6 Driving the Vehicle 2 4 2 7 Pre Operation Checklist 2 4 2 8 Parking 2 5 CHAPTER 3 ELECTRIC SYSTEM 3 1 Important Information 3 1 3 2 Battery Disconnect Methods 3 2 3 3 Battery Removal and Installation 3 2 3 4 Battery Inspection and Maintenance 3 2 3 5 Battery Cleaning 3 3 3 6 Conditions Which Affect Charging 3 3 3 7 Charger Information 3 4 3 8 Charger Operating Instruction...

Page 4: ...ch 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 1 3 SAFETY INFORMATION It is Columbia ParCar s specific recommendation that the following safety information must be observed at all times Not all are rep...

Page 5: ...perations 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 chains 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 a...

Page 6: ...lind crossings intersections etc Define who should and who should not drive the vehicles Enforce safe driving and operating rules Provide driver training for first time operators and review safe operating recommendations regularly Maintain vehicles in a safe operating condition and maintain a schedule for daily weekly monthly quarterly semi annually and annual vehicle inspections Determine who whe...

Page 7: ... digits The VIN can be found in two locations The VIN is recorded on the vehicle nameplate which is located on the left side of the operator s position See Figure 1 3 1 The nameplate also has other important information such as vehicle weights and capacity Do not exceed this capacity This rated capacity includes cargo and operator The VIN is also stamped on the metal cross bar located under the fo...

Page 8: ...CONTROLS This section describes the operating controls of the vehicle Figure 2 5 1 identifies the locations of many of these controls 2 5 1 KEYSWITCH Fig 2 5 1 A The keyswitch energizes the vehicle Rotate the key to the right from vertical to turn the vehicle on return to vertical to turn the vehicle off If equipped the keyswitch can also have a reverse direction Rotate the key to the left from ve...

Page 9: ...orn button is located on the left inside body panel and may be sounded by applying lateral pressure with the operator s left leg 2 5 4 CHARGER RECEPTACLE Fig 2 5 1 D The charger receptacle is for battery charging using the supplied AC cord 2 5 5 LOW BATTERY RESET SWITCH Fig 2 5 1 E The Low Battery Reset Switch is used if the battery is heavily over discharged See Section 3 8 2 5 6 CHARGING STATUS ...

Page 10: ...ctions blind spots or other dangerous locations Keep a clear view ahead at all times Slow and sound the horn when approaching a corner or other blind intersection Immediately report any accident or vehicle problem to your supervisor Do not load cargo that can easily fall off this vehicle Do not exceed the cargo load capacity of this vehicle 2 7 PRE OPERATION CHECKLIST Before operating the vehicle ...

Page 11: ...If you will be away from this vehicle turn off the keyswitch remove the key and take the key with you If you park this vehicle on an incline block the wheels Do not block fire aisles fire equipment or stairways 2 5 ...

Page 12: ...r batteries All batteries used in electric vehicles can explode Batteries produce explosive hydrogen gas at all times especially during charging or discharging Ventilate area when charging batteries Do not attempt to charge a battery if it is frozen or if the case is bulged excessively Frozen batteries can explode Do not smoke around batteries Keep sparks and flames away from batteries and the cha...

Page 13: ...attery configuration Disconnect both leads before performing any maintenance 3 3 BATTERY REMOVAL AND INSTALLATION Remove battery negative cable Remove battery positive cable Remove battery hold down Remove batteries from vehicle To install batteries reverse the removal procedure with the negative cable being attached last 3 4 BATTERY INSPECTION AND MAINTENANCE Check the electrolyte level on new ba...

Page 14: ...RY CLEANING Acid soaked dirt on the battery terminal connections causes current leakage reduces battery efficiency and battery life Check that all vent caps are tightly in place before washing Hose wash battery terminal connections periodically with clean low pressure water to keep them free of acid spillage dirt and other debris Do not hose wash switches solenoids and other electrical control dev...

Page 15: ...ed This occurs when each cell reaches approximately 2 5 volts 3 8 CHARGER OPERATING INSTRUCTIONS Plug 120 volt AC supply cord into charger receptacle on charger panel After a short time delay of approximately 5 to 6 seconds a RED light comes on indicating battery charging When the solid state circuitry senses that the batteries are fully charged the RED light turns off and the GREEN light turns on...

Page 16: ...OLONGING BATTERY LIFE To prolong battery life recharge batteries as soon as they become 20 or more discharged less than 1 238 sp gr Batteries may be recharged if vehicle has been driven 15 minutes or more since the previous charge Do not allow batteries to fall below 80 discharge 1 098 sp gr Deep discharging significantly reduces battery life Opportunity charging during breaks or shift change can ...

Page 17: ...ce exists Before starting the vehicle follow the recommended safety procedures in Chapter 1 SAFETY Avoid fire hazards and have fire protection equipment present in the work area Do not use flammable fluids for cleaning parts Work in a properly ventilated work area Regularly inspect and maintain in safe working condition the brakes steering mechanisms speed and directional control mechanisms warnin...

Page 18: ...backing plate retainer screws and tighten the screws then loosen each screw 1 4 turn Connect the upper end of the treadle to the brake assembly linkage and torque the nut to 120 inch pounds Temporarily install the brake shoes hub with drum sprocket assembly and castle nut on hub Depress rear of treadle to apply the brakes and to center brake assembly on spindle Carefully remove the castle nut hub ...

Page 19: ...to 200 foot pounds NOTICE Make sure that the handlebars and front fork spindle are properly aligned To remove the front wheel hub Place the front of the vehicle frame on blocks to allow for wheel removal Remove the nut and washer from the front axle C and pull the axle from the front fork to remove Remove the four lug nuts from the front hub To install the fronty wheel hub Install the hub on the f...

Page 20: ...otor adjusting screw several turns Slide the motor toward the rear of the vehicle and remove the drive chain Support the motor and remove the four mounting bolts Slide the motor to the left until the drive sprocket is clear of the frame and lift the motor up from the vehicle To install drive motor Place the motor in the frame with the wire terminals as shown in Figure 4 5 1 Once in place install t...

Page 21: ...a star pattern Insert the front axle through the front fork wheel spacers and hub Install the washer and nut on the front axle tighten the axle nut to 120 inch pounds Rear wheel hub removal See Figure 4 2 3 Raise the rear of the vehicle to allow the wheel to be removed Remove the four lug nuts holding the rear wheel to the rear hub and remove the wheel On the drive wheel side remove the drive chai...

Page 22: ...e mounting screws from each of the treadle mounts Figure 4 8 1 B Remove the lower mounting screws from each of the spindle s and remove the spindle s To install Install the lower mounting screws into the spindles Do not tighten Install two screws through the treadle mounts into the spindles Torque screws to 150 inch pounds Tighten the lower mounting screws securely with an open end wrench On the d...

Page 23: ...CLEANING Wash underside to remove all dirt and debris Do not direct high pressure water at the speed switch or tops of the batteries Wash body and seat with a mild detergent Do not use abrasives bodies are painted Frequent washings with mild soap will preserve the finish of your vehicle For stubborn and imbedded dirt a soft bristle brush may be used Tar asphalt creosote and the like should be remo...