Parts Manual. Chariot CR-10

Transcription

1 Parts Manual Chariot CR-10 4/2013

2 Preface Welcome, and congratulations on your choice of vehicle from Columbia ParCar Corp.! Your vehicle has been designed and manufactured to conform to applicable sections of ANSI B56.8. Your safe use and operation of your vehicle is important to us. Any alteration of your Columbia vehicle that results in the vehicle being in noncompliance with applicable ANSI standards is strictly prohibited. Columbia ParCar Corp. is not responsible or liable for any damage that results from any such alteration, and all warranties for any such altered vehicles are null and void. These vehicles are not designed for over-the-road use. They do not conform to Federal Motor Vehicle Safety Standards or EPA regulations, and are not equipped for operation on public streets, roads, or highways. 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 ParCar 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. This manual contains proprietary information that is protected by copyright. All rights are reserved. No part of this manual may be photocopied, reproduced, or translated to another language without the written consent of Columbia ParCar Corp. Columbia ParCar Corp. products are manufactured under one or more of the following U.S. Patents , , , , , , , , , , , , , Des Commercial Avenue Reedsburg, WI Phone: (608) Fax: (608) (800) Web: i

3 INDEX CR10 SECTION 1 BODY Body And Wheels Body Detail Hub Assembly Front & Left Rear -4 Hole Drive Hub and Brake Assembly SECTION 2 DRIVE SYSTEMS Drive System No Reverse Drive System Reverse Control Panel Assembly Forward Option Control Panel Assembly Forward Reverse Option Speed Control Switch Traction Motor SECTION 3 ELECTRICAL Hour Meter Installation Electrical Wiring Diagram Forward Only Electrical Wiring Diagram Forward and Reverse Main Wire Harness Schematic Battery And Hardware Battery Charger Schematic Keyswitch Information CHANGE HISTORY DATE DESCRIPTION BY 5/10/11 Issued TS 5/31/11 Improved knee pad attachment TS 8/17/11 Added knee pad kit p/n TS 4/9/12 Added Page 21 with keyswitch information TS 3/22/13 P/N increased length from.75 to.875 TS 4/11/13 Complete revision (ECR ) TS 12/4/13 Corrected wire diagram TS ii

4 CR 10 PARTS MANUAL SECTION 1 BODY

5 BODY & WHEELS - CR10 ITEM CPC P/N DESCRIPTION QTY SEATS P/N CHASSIS COVER CONTROL BS CAP SCREW COVER TO BODY 5/16-18 X.3/ B WASHER, FLAT, 5/16" B LOCK WASHER, 5/ * NUT, TINNERMAN CLIPPED TO BODY FRAME FENDER, L.H FENDER, R.H METER, BATTERY DISCHARGE INDICATOR, 12V N/A KEYSWITCH, SEE PAGE 21 FOR INFORMATION 1 N/A * NON-REMOVABLE KEY ASSEMBLY BUTTON, HORN CHARGER, BUILT-IN 12V HANDLEBAR, ASSEMBLY (Includes grip and clip) GRIP, HANDLE BAR" CLIP, STEMCO, 3", STAINLESS PAD, KNEE (ATTACHED WITH 7118 & 2685-W) LABEL, OPERATOR/WARNING SCREW, #10X3/4 SHWH, T/S * 7118 WASHER #10, I-TOOTH (behind item 17) * NUT, TINNERMAN (behind item 17) N/A NAMEPLATE TIRE/WHEEL ASSY, 4 HOLE, 4.8X8 PNEU, NON- MARKING A TIRE/WHEEL ASSY, 4.8X8 LRC B TIRE/WHEEL ASSY, FOAM FILLED 4.8X KNEE PAD KIT (Includes Item 21, P/N 7118 & 2685-W) U * NOT SHOWN 1-1

6 BODY DETAIL - CR10 1-2

7 BODY DETAIL - CR10 (Cont.) 1-3

8 BODY DETAIL - CR10 (Cont.) 1-4

9 BODY DETAIL - CR10 (Cont.) 1-5

10 BODY DETAIL - CR10 (Cont.) ITEM CPC P/N DESCRIPTION QTY SEATS P/N TREADLE SUPPORT ASSEMBLY SPINDLE ASSEMBLY TREADLE ASSEMBLY FORK ASSEMBLY, FRONT HANDLEBAR, ASSEMBLY (Includes grip and clip) A SPINDLE & CLUSTER ASSEMBLY * HUB/DRUM W/SPROCKET ASSEMBLY (See Item 46) * HUB/FRT & L RR, 4 HOLE ASSEMBLY (See Item 47) FRONT FORK SPACER, FRONT FORK SPACER, ROD, BRAKE LINK DECK, MEZZTREAD COTTER PIN SCREW, 5/16-18X1 HHC G WASHER, 3/ NUT, 1/ WHEEL BOLT (Included in Kit ) CAP, DUST ROD END, LOWER BEARING, (RH FEMALE) SPRING, TREADLE RETURN, 3/4 X 8-1/2" ROD END BEARING 1/4-28, MALE, BALL JOINT WASHER, DUST NUT, JAM, NYLON ¾-10X1/ W SCREW, 5/16-18X1 1/4, HHCS G W SCREW, 1/4-20X1 1/2 HEX CAP SCREW, 3/4-10X8 HHCS G B SCREW, HHC 1/4-20 X 3/ B SCREW, 1/4-20X2 1/2 HHCS FEMALE HEX STANDOFF 1/2X WASHER, CUPPED B WASHER, 5/ B WASHER ¼ B LOCKWASHER, 5/ NUT, 1/4-28 HEX LOCKNUT, NYLOK NUT, JAM NUT, JAM, NYLON B NUT, 1/4-20 GR A, SERRATED, FLNG, LOCK LOCKNUT, NYLOCK 5/ NUT, 3/4-16, SLOTTED, HEX G BEARING, CONE BEARING, CUP BEARING, TAPERED ROLLER W/SEAL KNEE PAD (Attached with 2 each P/N s 7118 & 2685-W) % 45** KNEE PAD KIT (Includes Item 44, 2 each P/N s 7118 & 2685-W) % 46** A ASSEMBLY, SPINDLE BRAKE HUB (Includes Items 6, 7, 13, 17, 18, 40, ** KIT, HUB FRNT &L RR 4H, (Includes Items 8, 16 & 43) * ONLY AVAILABLE AS A KIT ** NOT SHOWN NOTE: Include VIN to ensure proper color. 1-6

11 HUB ASSEMBLY Front & Left Rear -4 Hole - CR10 ITEM CPC P/N DESCRIPTION QTY SEATS P/N 1 * HUB WHEEL BOLT 1/2-20X1 1/ NUT, 1/ * BEARING CUP * BEARING, TAPERED ROLLER W/SEAL KIT, HUB BEARING, RACE & SEAL (includes Items 4 & 5) U KIT HUB ASSEMBLY (Includes Items 1-5) U * ONLY AVAILABLE AS A KIT 1-7

12 DRIVE HUB AND BRAKE ASSEMBLY - CR10 1-8

13 DRIVE HUB AND BRAKE ASSEMBLY - CR10 ITEM CPC P/N DESCRIPTION QTY SEATS P/N B WASHER, FLT 5/ TREADLE SUPPORT B LOCKWASHER, 5/ SPINDLE ASSEMBLY SPACER, BRAKE SCREW, HEX CAP 1/4-20X1 1/ ROD END BEARING 1/4-28, MALE, BALL JOINT NUT, 1/4-28 HEX ROD, BRAKE LINK B WASHER, PLAIN 1/ A BRAKE CLUSTER * BRAKE SPRINGS (used with Item 11) LOCKNUT, NYLOK BS SCREW, HEX CAP X3/ TUBE BRAKE LINK ROD END, LOWER BEARING, (RH FEMALE) LOCKNUT, NYLOCK 5/ W SCREW, HEX CAP 5/16-18X1 1/ B WASHER, LOCK ¼ CAP SCREW, 1/4-20 X 3/ KIT, HUB/DRUM W/BEARING U SPROCKET, 96 TOOTH # MASTER LINK, CHAIN # SPROCKET, 13 T, 3/16 KIT # A KEY (SPROCKET TO MOTOR) N/A CHAIN, #35, 55 LINK ( Only available with ) N/A CHAIN ASSY, #35, 55 LINK (Includes Item 22 and 25) SCREW, HEX CAP 8MM X 1 1/4 X 20MM BRAKE SHOE WHEEL BOLT (Included in Kit ) COTTER PIN NUT, ¾ CAP, DUST * NOT SHOWN 1-9

14 CR 10 PARTS MANUAL SECTION 2 DRIVE SYSTEMS

15 DRIVE SYSTEM - CR10 2-1

16 DRIVE SYSTEM - CR10 (Cont.) 2-2

17 DRIVE SYSTEM - CR10 (Cont.) 2-3

18 DRIVE SYSTEM - CR10 (Cont.) ITEM CPC P/N DESCRIPTION QTY SEATS P/N KEY SPROCKET CHAIN, #35, 55 LINK W/MASTER DRIVE ARM ASSEMBLY * CONTROL PANEL ASSEMBLY SCREW, M10X30, CL8 HHCS CABLE, 4 GA X 8.75, 5/16 TERM CABLE, 6GA X 14, 5/16 TERMINAL SWITCH, HORN BUTTON SPROCKET, 13 T, 3/16 KIT # LABEL, OPERATOR/WARNING MOTOR, TRACTION 12V WASHER, M10, LOCK WASHER, M10, 10MMX21MMX2.20MM NUT, TINNERMAN J-TYPE NUT, TINNERMAN, #10 U-TYPE SCREW, #10X3/4 SHWH, T/S SCREW, X 1/2 PPHM SCREW, HEX CAP 8MM X 1 1/4 X 20MM B SCREW, HHC 1/4-20 X 3/4, G BS SCREW, 5/16-18 X.3/4 HHC G BS SCREW, 5/16-18 X 2,PPH B WASHER, FLAT, 5/16" B WASHER 1/ B WASHER, LOCK 1/ B LOCK WASHER, 5/ WASHER #10, I-TOOTH LOCKNUT, 5/16-18 HEX FLG, WHIZ NUT, NYLOCK NUT, 1/ BATTERY BOX DECAL BDI METER 12V * Special Order NOTE: Include VIN to ensure correct colors. 2-4

19 DRIVE SYSTEM WITH REVERSE - CR10 2-5

20 DRIVE SYSTEM WITH REVERSE - CR10 (Cont.) 2-6

21 DRIVE SYSTEM WITH REVERSE - CR10 (Cont.) 2-7

22 DRIVE SYSTEM WITH REVERSE - CR10 (Cont.) ITEM CPC P/N DESCRIPTION QTY SEATS P/N KEY SPROCKET CHAIN, #35, 55 LINK W/MASTER DRIVE ARM ASSEMBLY * CONTROL PANEL ASSEMBLY W/REVERSE * BEEPER BRACKET SCREW, M10X30, CL8 HHCS CABLE, 6GA. X 14.00, 5/16 TERM SWITCH, HORN BUTTON SPROCKET, 13 T, 3/16 KIT # LABEL, OPERATOR/WARNING MOTOR, TRACTION 12V WASHER, M10, LOCK WASHER, M10, 10MMX21MMX2.20MM NUT, TINNERMAN J-TYPE NUT, TINNERMAN, #10 U-TYPE SCREW, #10X3/4 SHWH, T/S SCREW, X 1/2 PPHM SCREW, HEX CAP 8MM X 1 1/4 X 20MM B SCREW, HHC 1/4-20 X 3/4, G BS SCREW, 5/16-18 X.3/4 HHC G BS SCREW, 5/16-18 X 2,PPH B WASHER, FLAT, 5/16" B WASHER 1/ B WASHER, LOCK 1/ B LOCK WASHER, 5/ WASHER #10, I-TOOTH LOCKNUT, 5/16-18 HEX FLG, WHIZ NUT, NYLOCK NUT, 1/ BATTERY BOX DECAL A AUDIBLE ALARM, 12/48 VDC BDI METER 12V * Special Order NOTE: Include VIN to ensure correct colors. 2-8

23 CONTROL PANEL ASSEMBLY - FORWARD OPTION - CR UNMARKED HARDWARE INCLUDED WITH SOLENOID 11 ITEM CPC P/N DESCRIPTION QTY SEATS P/N SPEED SWITCH CONTROL ASSEMBLY SPACER ¼ X 5/ W SCREW, ¼-20X SOLENOID, 12V CIRCUIT BREAKER, 20 AMP SCREW, X ½ WASHER 3/ A HORN, 12V CABLE TIE MOUNTING BRACKET CABLE TIE, 5 ¾ TERMINAL, #10 STUD TO ¼ MALE TAB * COMPONENT PANEL * SPECIAL ORDER 2-9

24 CONTROL PANEL ASSEMBLY - FORWARD REVERSE OPTION - CR10 UNMARKED HARDWARE INCLUDED W/SOLENOID 5 6 o

25 CONTROL PANEL ASSEMBLY - FORWARD REVERSE OPTION - CR10 ITEM CPC P/N DESCRIPTION QTY SEATS P/N SPEED SWITCH CONTROL ASSEMBLY SPACER ¼ X 5/ W SCREW, ¼-20X CABLE, 6GA X 14, 5/16 TERMINAL B WASHER, 5/ RESISTANCE COIL, FWD/REV SWITCH B NUT, 5/ B LOCK WASHER, 5/ SOLENOID, DOUBLE 12V COILS SCREW, 5/16-18X1 ¼ CIRCUIT BREAKER, 20 AMP SCREW, X ½ WASHER 3/ A HORN, 12V CABLE TIE MOUNTING BRACKET CABLE TIE, 5 ¾ * A AUDIBLE ALARM N/A* KIT, FORWARD/REVERSE (Contains Items 4, 6, 9 & 17) U * NOT SHOWN 2-11

26 SPEED CONTROL SWITCH - CR

27 SPEED CONTROL SWITCH - CR10 (Cont.) ITEM CPC P/N DESCRIPTION QTY SEATS P/N B SCREW, HHC 1/4-20 X 3/ CONTACT BAR, 4-3/8" NEUTRAL BAR, M3A SWITCH INSULATOR, RED SLEEVE, INSULATING 1/4 X 3/ CPC SWITCH BASE INSULATOR, WHITE WASHER, ¼ STAR/INTERNAL LOCK B NUT, 1/4-20 BLACK SCREW, HEX CAP 1/4-20 X ½ HT WASHER, FIBER 3/4 X 1/4 X 1/ W NUT, NYLOK # WASHER, 3/ SCREW, MACHINE X 3/ SPRING, #13 7/16 X 2 1/ CABLE, 6 GA X CONTACT BAR, SLIDER SCREW, 10-24X1 1/ NUT, NYLOCK BEARING, NYLON W NUT, HEX # WASHER, BRASS #10S BEARING, NYLON SCREW, MACHINE X NUT, 3/8, PUSH ON RESISTANCE COIL (#7 NICROME WIRE) CABLE, 4 GA X 8.75, 5/16 TERM WASHER, #10 EXTERNAL TOOTH RESISTANCE COIL (#9 NICROME WIRE) DRIVE ARM BRACKET DRIVE ARM L-BRUSH DRIVE ARM, LOWER W SCREW ¼-20 X W SCREW X 5/ B WASHER ¼ NUT, ¼ SWITCH PANEL KIT (Includes Items 38 & 39) SPEED SWITCH CONTROL (Includes Items 1 thru 29) DRIVE ARM ASSEMBLY (Includes items 14, 21, 28, & 30 thru 37)

28 TRACTION MOTOR - CR ITEM CPC P/N DESCRIPTION QTY SEATS P/N 1 N/A HEADBAND, INSPECTION 1 N/A 2 N/A COMMUTATOR END FRAME 1 N/A A SPRING WASHER N/A BEARING BR N/A 5 N/A BRUSH LEAD ASSEMBLY 1 N/A 6 N/A BRUSH BOX ASSEMBLY 1 N/A BRUSH SPRING BRUSH N/A FRAME & FIELD ASSEMBLY 1 N/A 10 N/A ARMATURE ASSEMBLY 1 N/A 11 N/A RETAINING RING 1 N/A A BEARING BR N/A DRIVE END HEAD 1 N/A N/A MOTOR, TRACTION 12V

29 CR 10 PARTS MANUAL SECTION 3 ELECTRICAL

30 HOUR METER INSTALLATION - CR10 ITEM CPC P/N DESCRIPTION QTY SEATS P/N A BRACKET A HOUR METER VDC B SCREW, 10-16X3/4 HWH, TEK

31 ELECTRIC WIRING DIAGRAM FORWARD ONLY - CR NOT USED WITH ANALOG BDI 3-2

32 ELECTRIC WIRING DIAGRAM FORWARD ONLY - CR10 ITEM CPC P/N DESCRIPTION QTY SEATS P/N 1 ** CONTROL PANEL ASSY BATTERY, 6V, (US2200) BATTERY, 6V, (US145) SOLENOID, 12V CIRCUIT BREAKER, 20 AMP A HORN, 12V MOTOR, TRACTION 12V A KEY, SWITCH & HARDWARE A B B KEY, SWITCH & HARDWARE B C C KEY, SWITCH & HARDWARE C D D KEY, SWITCH & HARDWARE D E E KEY, SWITCH & HARDWARE E * KEY SET A * B KEY SET B * C KEY SET C * D KEY SET D * E KEY SET E * KEY SET A WITH NON-REMOVABLE COVER (Can only be used with Item 7A) BDI METER 12V CHARGER, 12V BUILT-IN SWITCH, HORN BUTTON CABLE 4 GA (SPEED SWITCH TO SOLENOID) CABLE, 6 GA CABLE, 6 GA (SPEED SWITCH TO A1) A HOUR METER * MAIN WIRE HARNESS * NOT SHOWN ** SPECIAL ORDER 3-3

33 ELECTRIC WIRING DIAGRAM FORWARD & REVERSE - CR NOT USED WITH ANALOG BDI 3-4

34 ELECTRIC WIRING DIAGRAM FORWARD & REVERSE - CR10 ITEM CPC P/N DESCRIPTION QTY SEATS P/N 1 * CONTROL PANEL ASSY W/REV BATTERY, 6V, (US2200) BATTERY, 6V, (US145) SOLENOID, DOUBLE 12V CIRCUIT BREAKER, 20 AMP A HORN, 12V MOTOR, TRACTION 12V A KEY, SWITCH & HARDWARE A B B KEY, SWITCH & HARDWARE B C C KEY, SWITCH & HARDWARE C D D KEY, SWITCH & HARDWARE D E E KEY, SWITCH & HARDWARE E * KEY SET A * B KEY SET B * C KEY SET C * D KEY SET D * E KEY SET E * KEY SET A WITH NON-REMOVABLE COVER (Can only be used with Item 7A) BDI METER 12V CHARGER, 12V BUILT-IN SWITCH, HORN BUTTON CABLE 4 GA (SPEED SWITCH TO SOLENOID) CABLE, 6 GA CABLE, 6 GA (SPEED SWITCH TO A1) A HOUR METER A AUDIBLE ALARM * MAIN WIRE HARNESS * NOT SHOWN * SPECIAL ORDER 3-5

35 MAIN WIRE HARNESS SCHEMATIC - CR10 3-6

36 MAIN WIRE HARNESS SCHEMATIC - CR10 3-7

37 BATTERY AND HARDWARE - CR10 ITEM CPC P/N DESCRIPTION QTY SEATS P/N BATTERY SEPARATOR LABEL, SMALL VIN PLATE, HOLD DOWN CABLE, 4 GA X 8.75, 5/16 TERM A ROD, HOLD DOWN BATTERY, 6V DEEP CYCLE US A* BATTERY, 6V DEEP CYCLE US WASHER, FLAT, STAINLESS.28X.375X NUT, 1/4-20 STAINLESS NYLON * NOT SHOWN 3-8

38 BATTERY CHARGER SCHEMATIC - CR TRANSFORMER 2 4 AC INPUT RECEPTICLE AC FUSE AC FUSE BLOCK DC CIRCUIT BREAKER CAPACITOR ITEM CPC P/N DESCRIPTION QTY SEATS P/N AUTO-START CONTROL BOARD RECTIFIER LOW BATTERY RESET SWITCH STATE OF CHARGE METER * A AC POWER CORD CHARGER, COMPLETE W/CORD

39 KEYSWITCH INFORMATION- CR10 See Note Plate 1 ITEM CPC P/N DESCRIPTION QTY SEATS P/N 1A KEYSWITCH, UNIVERSAL A W/HARDWARE B B KEYSWITCH, UNIVERSAL B W/HARDWARE C C KEYSWITCH, UNIVERSAL C W/HARDWARE D D KEYSWITCH, UNIVERSAL D W/HARDWARE E E KEYSWITCH, UNIVERSAL E W/HARDWARE * NON-REMOVABLE KEY ASSEMBLY * NOT SHOWN NOTE: 1. Vehicles with circular keyswitch holes must have serrated washers installed on each side of the charger plate. The use of one serrated washer may result in rotation of the switch. Contact Columbia Parts Department for an additional washer. 2. Replacement keyswitches include two serrated washers 3-10