Columbia ParCar Expediter EX21-24S User manual

Columbia ParCar Corp.
SERVICE MANUAL
Expediter™
EX21-24S
EX21-24A
EX21-48A
2013

Table of Contents
GENERAL
This service manual has been prepared with two purposes.
First, it will introduce the trained maintenance professional to
the latest field tested and factory approved major repair
methods. Secondly, it will acquaint the reader with the
construction of the Columbia ParCar vehicles and assist
him/her in performing basic maintenance and repair. We
sincerely believe that this manual will make the association
with Columbia ParCar vehicles a more pleasant and
profitable experience.
In addition to the information given in this manual, Service
Bulletins are issued to Columbia ParCar dealers 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 our vehicles and to
protect the vehicles from possible damage resulting from
improper service or maintenance, the procedures in this
manual should always be followed exactly as specified.
Execution of the procedures and troubleshooting tips as
outlined will ensure the best possible service from the
vehicle(s). To reduce the chance of personal injury and/or
property damage, carefully observe the DANGER,
WARNING, CAUTION & NOTICE recommendations
throughout this manual. See Section 1 Safety for additional
details.
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 Par-Car
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.
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 beginning of each section.
MODEL IDENTIFICATION
Always give the vehicle identification number (VIN) when
ordering parts or making inquiries about the vehicle. Use of
the full and complete vehicle identification number will
ensure that the dealer or service provider is supplying you
with the correct parts for the vehicle. See Section 2General
Information for VIN location and additional information.
USE GENUINE REPLACEMENT PARTS
When replacement parts are required, use only genuine
Columbia ParCar parts or parts with equivalent
characteristics including type, strength and material.
Failure to do so could result in product malfunction and
possible injury to the operator and/or passenger.
To ensure a satisfactory and lasting repair, follow the service
manual instructions carefully and use only genuine Columbia
ParCar vehicle replacement parts. This is the insurance that
the parts you are using will fit right, operate properly and last
longer. When you use genuine Columbia ParCar vehicle
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.
SECTION 1 - SAFETY
Overview .............................................................. 1-1
Safety Information ................................................ 1-1
Antidotes .............................................................. 1-1
Safety Preparations .............................................. 1-2
Decals .................................................................. 1-2
SECTION 2 - GENERAL INFORMATION
Vehicle Description ............................................... 2-1
Vehicle Identification Number (Vin) ...................... 2-1
Vin Matrix.............................................................. 2-1
Safety Committee ................................................. 2-2
Operation .............................................................. 2-2
Vehicle Specifications ........................................... 2-2
Vehicle Controls .................................................. 2-3
Pre-Operation Inspections .................................... 2-4 Pre-
Operation Checklist. ...................................... 2-4
SECTION 3 –MAINTENANCE
Electric Vehicle Service ........................................ 3-1
Periodic Maintenance ........................................... 3-1
Batteries ............................................................... 3-3
Chassis Lubrication .............................................. 3-3
Wheel Hub ............................................................ 3-3 Brake
Pedal .......................................................... 3-3 Rear Axle
.............................................................. 3-3 Chassis
Cleaning .................................................. 3-3 Seat Cleaning
....................................................... 3-3
Lifting Instructions ................................................. 3-3

Table of Contents
Tools Required ..................................................... 3-3 Hoist
Lifts .............................................................. 3-4
Hoisting the Rear of Vehicle .................................
3-4 Hoisting the front of Vehicle ..................................
3-4
Floor Jack Procedure ........................................... 3-4
Lifting the Rear of Vehicle .................................... 3-4
Lifting the Front of Vehicle .................................... 3-4
Jack Stands .......................................................... 3-4
Vehicle Storage .................................................... 3-4
Returning Vehicle To Service ............................... 3-5
Transporting the Vehicle ....................................... 3-5
Torques and Metric Conversion Factors ............... 3-6
SECTION 4 - TROUBLE SHOOTING
Pre-Troubleshooting Steps ................................... 4-1
Battery Testing ..................................................... 4-1
Troubleshooting Specific Complaints ................... 4-2
Troubleshooting with PCPAK ............................... 4-2
Troubleshooting with handheld Calibrator ............ 4-4
Vehicle Drives Slowly ........................................... 4-5
Vehicle Drives in Forward or Reverse Only .......... 4-5
Vehicle Drives but Operation
is Jerky or Inconsistent ......................................... 4-5
Vehicle Power Cuts Out ....................................... 4-5
Flash Codes and
Corrective/Investigative Action ............................. 4-6
Component Troubleshooting ................................ 4-7
SECTION 5 –ACCELERATOR & BRAKE SYSTEM
Accelerator Pedal .................................................. 5-1
Mechanical Brake System..................................... 5-1
General ................................................................. 5-1
Periodic Brake Inspection ..................................... 5-1
Annual Brake Inspection ....................................... 5-1
Mechanical Rear Drum Brake ............................... 5-2
Disassembly .......................................................... 5-2
Brake Drum Service .............................................. 5-3
Reassembly .......................................................... 5-3
Brake Strip Replacement ...................................... 5-4
Mechanical Brake Adjustments ............................. 5-4
Linkage Adjustment .............................................. 5-4
Drum Brake Shoe Adjustment ............................... 5-5
SECTION 6 - FRONT WHEELS, FORK & STEERING
General ................................................................. 6-1
Front Wheels and Hubs ........................................ 6-1
Inspecting/Replacing Wheel 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
Steering Wheel Equipper Model ........................... 6-3
Removing Steering Wheel .................................... 6-3
Replacing Steering Shaft Bearings ....................... 6-3
Installing Steering Wheel ...................................... 6-3
Upper Steering Group ........................................... 6-3
Disassembly .......................................................... 6-3
Assembly .............................................................. 6-3
Front Suspension Fork –3 Wheel ......................... 6-4
Removal ................................................................ 6-5
Installing ................................................................ 6-5
Front Non-suspension Fork –3 Wheel ................. 6-5
Front Suspension –4 Wheel ................................. 6-5
Replacing Tie Rods ............................................... 6-5
Replacing Bushings .............................................. 6-7
SECTION 7 - REAR WHEELS, REAR SUSPENSION &
AXLE ASSEMBLY
Rear Wheels ......................................................... 7-1
Removing Rear Wheels ........................................ 7-1
Rear Axle Wheel Bearings .................................... 7-1
Installing Rear Wheels .......................................... 7-1
Tires ...................................................................... 7-1
Rear Suspension .................................................. 7-1
Replacing Rear Shock Absorbers ......................... 7-1
Replacing Rear Springs ........................................ 7-1
Rear Axle Assembly .............................................. 7-2
Removing Rear Axle ............................................. 7-2
General ................................................................. 7-3
Torques ................................................................. 7-3
Disassembling Rear Axle ......................................
7-5 Assembling Rear Axle ...........................................
7-8
Installing Rear Axle ............................................... 7-10
Rear Axle Differential Oil ....................................... 7-10
Changing Differential Oil ....................................... 7-10
SECTION 8 –BODY & CHASSIS
Front Bumper........................................................ 8-1 Horn
...................................................................... 8-1
Cargo Deck........................................................... 8-1
Controls and Console ........................................... 8-1
Battery Charger Indicator ..................................... 8-1
Hour Meter............................................................ 8-1
On/Off Key switch ................................................. 8-1
Directional Key Switch .......................................... 8-1
Horn Button .......................................................... 8-2 Seats
.................................................................... 8-2
Seat Back ............................................................. 8-2
Handrails .............................................................. 8-2
Brake Light ........................................................... 8-3
Fuse Block ............................................................ 8-3
SECTION 9 –BATTERIES & BATTERY CHARGER
Important Information ........................................... 9-1
Safety Information ................................................ 9-1
Antidotes .............................................................. 9-1
Battery Inspection & Maintenance ........................ 9-1
Battery Cleaning ................................................... 9-1

Table of Contents
Battery Service (Water) ........................................ 9-2
Adding Water ........................................................ 9-2
Single Point Watering System .............................. 9-2
Battery Charging ................................................... 9-3
Charger Safety Information ..................................
9-3 Battery Brand Algorithms ......................................
9-4 Delta-Q Charger Operation...................................
9-5
Single LED Display ............................................... 9-6 Red
Light Charger Error Codes ............................ 9-6 Charging
Procedure ............................................. 9-6
Testing Batteries ................................................... 9-6
Specific Gravity Test ............................................. 9-6
Hydrometer Test ...................................................
9-6 Discharge (Load) Test ..........................................
9-7
Test Preparation ................................................... 9-7
Test Procedure ..................................................... 9-7
Results Interpretation ............................................ 9-8
Storing Batteries ................................................... 9-8
Excessively Discharged Batteries ......................... 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
External Inspection ............................................... 10-1
Internal Inspection ................................................. 10-1
Removal ................................................................ 10-1
Disassembly .......................................................... 10-2
Armature Inspection .............................................. 10-2
Armature Testing .................................................. 10-3
Brushes ................................................................. 10-3
Brush Springs ....................................................... 10-3
Bearing ................................................................. 10-5
Frame and Field Coils ........................................... 10-5
Field Coil Maintenance ......................................... 10-5
Inspection.............................................................. 10-5
Motor Reassembly ................................................ 10-5
Motor Installation ................................................... 10-6
Controller .............................................................. 10-7
ACEplus System ................................................... 10-7
Testing .................................................................. 10-7
Removing .............................................................. 10-7
Installing ............................................................... 10-7
Contactor/Solenoid ............................................... 10-8
Removing .............................................................. 10-8
Installing the Contactor ......................................... 10-8
CHANGE HISTORY- EX-21
DATE
DESCRIPTION
BY
12/9/13
Issued
TS

Service Manual
Section 1
Safety
OVERVIEW
Statements in this manual preceded by the words DANGER,
WARNING, CAUTION or NOTICE and words printed in bold
face are very important. We recommend you take special
notice of these items.
Danger indicates a hazardous situation which, if not
avoided, will result in death or serious injury.
Warning indicates a hazardous situation which, if not
avoided, could result in death or serious injury.
Caution indicates a hazardous situation which, 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.
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 inclusive.
Since Columbia ParCar Corporation could not possibly know,
evaluate and advise servicing personnel of all possible ways in
which service might be performed or of the possible hazardous
Section 1 - Safety

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 him/herself that neither their nor the
operator’s safety will be jeopardized by the service methods
selected.
SAFETY INFORMATION
It is Columbia ParCar’s specific recommendation that the
following safety information 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) are encountered.
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 keys and turn the master
disconnect switch counterclockwise to the OFF
position before servicing or repairing your vehicle. See
Section 8-Batteries, for specific details.
All batteries used in 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 around electric vehicle batteries. Keep
sparks and flames away from batteries. Battery
charging should only be done in a well-ventilated area.
Refer to Section 9-Batteries for details.
Batteries contain acid which can cause severe burns.
Avoid contact with skin, eyes, or clothing. Wear full
face shield and rubber gloves when 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 with water for fifteen minutes. Call a
physician immediately.
When working around batteries, use approved
insulated tools, remove jewelry such as rings, watches,
chains, etc. and place an insulating material such as
wood, plastic, rubber, etc. over batteries covering all
connections.
If any problems are found during scheduled
maintenance or inspections, do not operate vehicle
until repairs are completed. Failure to make necessary
repairs could result in fire, property damage, severe
personal injury or death.
Only trained maintenance professionals should repair
or service this vehicle. Persons performing 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 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.
Use insulated tools when working near batteries or
electrical connections. Use extreme caution to avoid
shorting of components or wiring.
Do not wear loose clothing or jewelry such as rings,
watches, chains, etc. when servicing the vehicle.
Failure to do so could result in personal injuryor death.
2013 EX-21 Service Manual 1-1

Working on Columbia ParCar vehicles without
following proper procedures and using proper lifting
equipment may result in vehicle damage or personal
injury. See Section 3 - Lifting Instructions detailed
instructions.
Always wear safetyglasses or approved eye protection
while servicing vehicle. Wear a full face shield when
working with batteries.
Failure to maintain vehicle properly could result in
decreased vehicle performance, reliability or cause
severe personal injury.
Exceeding rated vehicle load capacities could result in
possible severe injury or property damage.
Check the vehicle for proper location and condition of
all vehicle safety and operation decals. Refer 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 vehicle is designed to transport one (1) operator and one
passenger.
SAFETY PREPARATIONS
Before performing any service on the vehicle, always
turn Power keyswitch to OFF and remove. Turn.
Directional knob to NEUTRAL. Block tires.
DECAL
All decals should be ordered and replaced as soon as they are
discovered to be illegible or missing. Section 1 - Safety
Part number for the Warning/Operating decal set is 53282-96
(Figure 1-1).
Part number for a Power Information decal is 71527-04
(Figure 1-2).
Figure 1-2
To remove a decal, use a heat gun or hair dryer to soften up
and remove any damaged sticker. Peel off backing of the new
decal and carefully position in place.
1-2
Figure 1
-
1

Service Manual
Section 2
General Information

VEHICLE DESCRIPTION
The EX-21 Expediter is an electric three or four wheel vehicle. It
is designed for one person and load or two persons (one facing
the rear).
This vehicle is designed to be driven over smooth surfaces in
and around places such as warehouses, factories, industrial sites, motels,
parks, and resorts.
It is not approved
for use on public
highways.
Each vehicle is
assigned a unique
Vehicle
Identification Number (VIN). The VIN describes facts and features of the vehicle and contains thirteen (13) digits.
The VIN number can be found in two locations. Under the rear deck, stamped inthe right front corner of the rear body chassis
as shown in Figure 2.1. It is also on the vehicle nameplate located on the vertical panel below the seat as shown in
Figure 2.2.
The nameplate has important information such as model,
ET2C2-3ZG1234 is an
example of a current
VIN.
It is designed to conform 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 and Burden
Carriers (ANSI B56.8 2006 Part III).
VEHICLE IDENTIFICATION NUMBER (VIN)
Figure 2-1
Do not remove any nameplate, warnings, or
instructions affixed to your Columbia Industrial
Vehicle. Promptly replace any that become damaged or
removed.
vehicle weights and rated capacity (load, operator and passenger).
Do not exceed this rated capacity. Read carefully.
To ensure prompt service when repairs or adjustments are
required, your Columbia Dealer must have the VIN.
VIN MATRIX
Digit 1 thru 3 =
Abbreviation (Model)
ET2 (Three Wheel) EF2
(Four Wheel)
Digit 4 = Power System
E = Sep Ex, Regen:
(ACEplus)
Digit 5 = System Voltage
2 = 24V (4 –6 V)
B = 48V (4 –12V)
Digit 6 = VIN Spacer
- = normal
# = Special Product
Digit 7= Controller
Amperage
3 = 300 Amp
4 = 400 Amp
Digit 8 = Axle/Brake System
Z = Rear Mechanical
Digit 9 = Build Year
L = 2012, M = 2013, N =2014,
etc.
Digit 10 Thru 13 –Build
Sequence
1234
Section 2
–
General Informatio
n
Figure 2
-
2

Section 2
–
General Information
SAFETY COMMITTEE
If the 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 are not limited
to, the following:
•Define where the vehicles should and should not be driven
and utilized.
•Ensure all proper warnings as to driving hazards are
properly displayed and visible.
•Safety signage concerning hills, turns, blind crossings or
intersections is highly recommended.
•Enforcement of 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. Maintain
a schedule for daily, weekly, and monthly vehicle
inspections.
•Determine who, when and how pre-operation inspections
should be conducted.
•Enforcement of safe driving and operating rules.
•Define who should and who should not drive the vehicles.
•Decide what to do should an unsafe condition or operating
problem be discovered.
•Enforce that vehicle should not be operated by persons
under the age of 16.
These basic rules of operation, combined with courtesy and
common sense, will help make driving your Columbia ParCar
Vehicles a safe 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 directional key switch to the desired direction of
travel (F=Forward, R=Reverse).
4. Depress accelerator with the right foot.
5. To stop the vehicle, release the accelerator pedal and
apply the brake pedal slowly and completely.
To avoid injury, speed in reverse should always be kept
at a minimum.
Be sure the direction selector is in the desired direction
of travel before depressing the accelerator pedal.
VEHICLE SPECIFICATIONS
Columbia ParCar Corporation reserves the right to change
specifications, equipment or designs at any time without
notice and without incurring obligations
EX21 T
24
EX21 F
24
EX21 T
48
EX21 F
48
Passenger
Capacity
One or Two
Max. Speed
8 mph
Turning Curb to
Curb (in)
127
175
127
175
Turning
Intersecting Aisle
(in)
66
83
66
83
Ground
Clearance (in)
4
Wheelbase (in)
53.5
Overall Length
(in)
84
Overall Width (in)
28.5
Overall Height
(in)
46.5
Bed Size L x W
(in)
21.5 x 26.0
Weight (lbs)
855
940
1100
1183
Rated Capacity
750 lbs.
Towing Capacity
1000 lbs.
Horsepower
5.2 HP @ 875 rpm
15.3 HP @ 1750
rpm
Differential
12.44:1
16.99:1
Battery
(Deep Cycle)
Four 6V, 225 amp
hour
Four 12V, 145
amp hour
Controller Rating
300 amp
400 amp
Controller Type
Programmable, solid state, reduced
speed reverse w/diagnostic LED &
calibrator interface
Charger
Built in, micro-processor controlled,
fully sealed, global 110-240 V AC,
50/60 Hz