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

Section 2
–
General Information
Motor Braking
Mode
Regenerative & accelerator pedal
proportional
Directional
Control
Fully electronic direction switching
with console selector switch
Drive Unit
Automotive style, helical gears in oil
bath, direct to motor
Brakes
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 SELECTOR
C - SYSTEM STATUS LIGHT
D - HORN BUTTON
E - LIGHT SWITCH (option)
F - BATTERY DISCHARGE METER (BDI) G - HOUR METER
INDICATOR (option)
H - OPERATING INSTRUCTION
I - ACCELERATOR PEDAL
J - BRAKE PEDAL/PARKING BRAKE
K - WARNING LABEL
L –IMPORTANT POWER INFORMATION
VEHICLE CONTROLS

Section 2
–
General Information
PRE-OPERATION INSPECTIONS
Each vehicle has been inspected and adjusted to factory
specifications before delivery. Upon receipt of vehicle, perform 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
working order.
Only trained maintenance professionals should service
or repair this vehicle. Persons performing even simple
repairs or service should have a 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.
PRE-OPERATION CHECKLIST
ITEM
PROCEDURE
Batteries
Fully charged or adequately charged to provide power for duration of operations.
The AC cord is disconnected from the vehicle.
Electrolyte level 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 are tight.
Tire
See page 2.2 recommendations for tire pressure. Free from damage.
Lights, Horn and Reverse Buzzer
If equipped, turn lights on and make sure they illuminate.
Press horn button to sound horn.
Reverse buzzer operating. (Operator seat must be occupied.)
Brakes
Brake pedal has firm pedal pressure with minimal travel.
Brake light illuminates.
Parking brake has proper engagement and release.
Steering
Responsiveness and absence of excessive free play. See Section 6.
Cargo
Load secured, balanced and not top heavy.
Obstacles
Path of intended travel is free for obstructions.
Labels
All warning and operation labels in place.
Accelerator
Check for smooth operation.
Vehicle Body
Visually check for damaged or loose hardware. See Section 8.
Should any item malfunction or need adjustment. Do not
operate vehicle until the problem has been corrected.

Section 2
–
General Information

Service Manual
Section 3
Maintenance
Always turn 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
and possible personal injury.
PERIODIC MAINTENANCE
A comprehensive maintenance program is important for the
safe, reliable operation of all Columbia ParCar vehicles. The
recommended procedures described in this service manual are
effective methods for performing periodic maintenance and
repair. The maintenance procedures outlined in this manual are
recommended when servicing the vehicle. Refer to
maintenance check-list for 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 technical experience,
training and original Columbia vehicle parts for the vehicle.
Always use original Columbia vehicle parts when servicing
the vehicle.
NOTICE: Some procedures require the use of
special tools. These special tools must be used
when and where recommended.
NOTICE: When performing Monthly, Quarterly,
SemiAnnual or Annual maintenance, ensure that Daily
and Weekly inspections are included.
NOTICE: The environment that the vehicle operates in
can vary widely. Severe service operations will
require the periodic maintenance recommendations
to be adjusted to shorter time intervals. The following
calendar is one example of how scheduling routine
maintenance can be managed.

3-1
Section 3
–
Maintenance
NOTICE: Daily
maintenance is
performed daily before
operation of vehicle by
owner or operator.
Weekly maintenance
is performed on a
weekly basis to
include all daily maintenances and is performed by the owner, operator or trained
maintenance personnel.
MAINTENANCE SCHEDULE CHECKLIST –BODY/FRAME/CHASSIS
Component
Procedure
Daily1
Weekly1,2
Monthly2
Quaterly2
(25 Hours)
Semi-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 Labels
In place and
readable
X
EXT21-F
Front Steering
Lubricate
X
Brake Pedal
Lubricate
X
12
Service done by owner. Service done by trained maintenance personnel
MAINTENANCE SCHEDULE CHECKLIST - ELECTRICAL
Component
Procedure
Daily*
Weekly
Monthly†
Quarterly†
(25 hours)
Semi-Annual†
(50 hours)
Annual†
(100 hours)
Batteries
Check charge
X
Check electrolyte
level
X
Apply equalization
charge to battery
pack
X

3-2
Section 3
–
Maintenance
Clean terminals and
wash battery case
X
Test batteries
X
Electrical
wires
Check for tightness
or damage
X
Reverse
warning
buzzer
Check for operation
(use keyswitch)
X
* Service done by Owner †Service done by trained maintenance personnel
MAINTENANCE SCHEDULE CHECKLIST - TIRES & WHEELS
Component
Procedure
Daily*
Weekly
Monthly
†
Quarterly†
(25 hours)
Semi-Annual†
(50 hours)
Annual†
(100 hours)
Tires
Check for 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 nuts for
tightness & torque
x
Steering
linkage
Check for excessive
movement & that
hardware is secure
x
* Service performed by Owner † Service performed by trained maintenance personnel
MAINTENANCE SCHEDULE CHECKLIST –FLUIDS
Component
Procedure
Daily1
Weekly1,2
Monthly2
Quaterly2
(25 Hours)
Semi-annual2
(50 Hours)
Annual2
Differential lubricant
Check level
X
12
Service done by owner. Service done by trained maintenance personnel

3-3
Section 3
–
Maintenance
BATTERIES
Batteries may be recharged if vehicle has been driven 15
minutes or more since the previous charge. Before charging,
be sure master power key switch is Off and key is removed from
the switch.
Refer to Chapter 9 for all procedures relating to the batteries.
CHASSIS LUBRICATION Wheel Hubs –EXT21-F
The vehicle has 2 grease fittings, one in each wheel hub. See
Section 6 - Front Wheels and Hubs.
Brake Pedal
The brake pedal assembly has one fitting located under the
vehicle. See Section 5 –Accelerator and Brake System.
REAR AXLE
Check the rear axle oil only if signs of leakage are detected.
Change oil at 24 months or 1250 mile (2000 km) intervals,
whichever occurs first. Refer to Section 7.
Capacity - 12 ounces (360 ml). Light weight gear lubricant SAE
#30 oil.
CHASSIS CLEANING
Proper cleaning materials and techniques are vital to the care
of the vehicle. Wash underside of vehicle to remove all dirt and
debris. Wash chassis and body with a mild detergent only. Do
not use abrasives on the paint.
Do not direct high pressure water at the controller,
speed switch, or top of batteries. Dry the controller and
top surfaces of the batteries immediately after washing.
SEAT CLEANING
Proper cleaning will extend the life of the vehicle seat. Use mild
soap or detergent and a soft sponge to clean whenever
necessary. For stubborn or imbedded dirt, a soft bristle brush
may be used.
NOTICE: Do not use harsh chemicals or abrasives to
clean seat material. 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
vehicle. Vehicle should be lifted only when parked on a
flat, hard and level surface. Do not work under the
vehicle unless it is firmly supported on jack stands.
When lifting the vehicle for service, use a sturdy lifting
device such as a floor jack or hydraulic lift. Always,
wedge wheels and set parking brake of the vehicle to
keep it from rolling. When using a lifting device, lift only
on sturdy parts under the vehicle, an example being the
frame. When using a floor jack, lift only on sturdy parts
under the vehicle, an example being the frame or axle
housing. Place jack stands or sup-port blocks under
vehicle frame to support vehicle weight for added
safety. Watch for cables, linkages or wire harness.
If any vehicle is raised while loaded, check that the load
is secured before lifting vehicle. Failure to do so could
cause damage to load, vehicle, or personal injury.
Before lifting, always chock tires. Use care to prevent
tipping or rolling over. Be careful not to damage the
brake cables during lifting operation.
TOOLS REQUIRED
- hydraulic trolley jack
- chocks or wooden blocks
- jack stands or support blocks
HOIST LIFTS
MAINTENANCE SCHEDULE CHECKLIST –ELECTRIC MOTOR
Component
Procedure
Daily1
Weekly1,2
Monthly2
Quaterly2
(25 Hours)
Semi-annual2
(50 Hours)
Annual2
Operation
Test drive for proper
operation
X
Motor
Inspect brush length &
remove carbon dust Inspect
& apply anti-seize to
splines
X
12
Service done by owner. Service done by trained maintenance personnel

3-4
Section 3
–
Maintenance
If a hoist is used to lift the vehicle, check that the hoist is rated
at a capacity greater than the vehicle weight. Lift the vehicle
sufficiently from the floor, 10° to 25° angle, to allow the
placement of jack stands to support the weight of the vehicle
during service. See figure 3-1.
HOISTING THE REAR OF VEHICLE
1. To lift the rear, connect the lifting eyes/hooks to rear frame
tubes at right and left sides. Do not use the bumper for
lifting. Hoist vehicle sufficiently to place jack stands
underneath frame.
2. Place jack stands under frame at right and left sides to
allow access under the vehicle.
3. When work is completed, lift the vehicle and remove the
jack stands, then lower vehicle to the floor.
HOISTING THE FRONT OF VEHICLE
1. To lift the front, connect the lifting eye/hooks to front frame
tubes at right and left sides. Do not use the bumper for
lifting.
2. Place jack stands under frame at right and left sides to
allow access under vehicle.
3. When work is completed, lift the vehicle and remove the
jack stands, then lower vehicle to the floor.
FLOOR JACK PROCEDURE
If a floor jack is used to lift the vehicle, check that the floor jack
is rated at a capacity greater than the vehicle weight. Lift the
vehicle sufficiently from the floor to allow the placement of jack
stands or wooden blocks and hold the weight of the vehicle
during service.
LIFTING THE REAR OF VEHICLE
1 To lift the rear, place floor jack under the rear axle housing.
Do not use the bumper for lifting. Raise vehicle sufficiently
to place jack stands underneath 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 jack stands, then
lower vehicle to the floor.
LIFTING THE FRONT OF VEHICLE
1. To lift the front, place floor jack under the heavy leaf spring
retainer plate. Do not use the bumper for lifting. Raise
vehicle sufficiently to place jack stands underneath 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 leaf spring
retainer plate, lift the vehicle and remove the jack stands,
then lower vehicle to the floor.
JACK STANDS
Jack stands need to be of sufficient rated load capacity to hold
the vehicle safely. See Section 2 - Vehicle Specification Chart
for empty vehicle weight.
VEHICLE STORAGE
Turn Power keyswitch OFF. Remove Power key during
storage to prevent unintentional starting of vehicle.
Do not attempt to charge a battery that is frozen or if
battery case is excessively bulged. Frozen batteries
can explode. Properly dispose of battery.
Electric vehicles stored over 6 to 8 weeks must be protected to
maintain battery life. Several guidelines should be observed
when storing the electric vehicle.
The Delta-Q charger has the capability to test and recharge
batteries during storage. Leave the batteriesconnected and the
Delta-Q charger plugged into a reliable AC source.
If the Delta-Q is not used:
1. Batteries will "self-discharge” during storage and
recharging will be necessary. Frequency for recharging is
as follows:
STORAGE TEMPERATURE
CHARGE AT
Below 40 C (400F)
Every 6 months
40 C - 160C (400–600F)
Every 2 months
Above 160C (600F)
Once a month
Figure 3
-
1

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.

Section 3
–
Maintenance
Batteries in a low state of charge will freeze at higher
temperatures than fully charged batteries. Do not
attempt to charge a battery that is frozen or if battery
case is excessively bulged. Properly dispose of battery,
because frozen batteries can explode.
3. Freezing points of batteries at different specific gravities
is shown below.
O O
NOTICE: Specific gravity readings are at 80 0F. Values
need adjustment for electrolyte temperature. Reduce
.004 for every 100F below 800F. Increase by that amount
for every 100F above.
4. For vehicles with a single point watering system, check
water levels quarterly per Section 9.
5. Charge batteries fully then check fluid levels. Store
batteries in as cool place as possible.
6. Disconnect battery negative terminal.
7. Wash off any corrosion around the terminals with a
solution of baking soda and water. Do not allow this
solution to enter batteries.
8. Do not engage parking brake. Block wheels to prevent
movement.
RETURNING VEHICLE TO SERVICE:
1. Reconnect battery negative terminal.
2. Fully recharge batteries and check fluid levels.
For vehicles with a single point watering system: After the
batteries have been fully charged, connect the system to
its water supply for 3-5 seconds then disconnect
regardless of whether or not the batteries are completely
full. 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. Perform initial maintenance per periodic maintenance in the
beginning of this section.
6. Return the vehicle to its regular service.
TRANSPORTING A VEHICLE
NOTICE: Never tow a vehicle behind an auto or truck
unless on an approved trailer.
When trailering a vehicle over long distances or on the highway
observe the following:
1. Use trailers specifically designed to carry your Columbia
ParCar vehicle that meets all federal, state and local
requirements.
2. Secure vehicle to the trailer following trailer manufacturer’s
instruction.
3. The key should be removed from the vehicle, the parking
brake firmly locked, and the wheels blocked.
4. On vehicles equipped with high or wide additions or
accessories be certain they are secured properly to
prevent loss or damage.
Use care when transporting on windy days. Example: A
60 MPH speed into a 40 MPH head wind is equal to
traveling at 100 MPH. Industrial vehicles are not rated
to withstand this level of stress and parts could be
blown off, causing accident or injury.
3-5
3-6
TORQUES AND METRIC CONVERSION FACTORS
Individual component torques and metric equivalents are listed where the maintenance is tobe performed throughout this manual.
When a specific fastener torque is not specified,
SPECIFIC GRAVITY
FREEZE POINT
F/ C
1.260
-70/-57
1.230
-39/-38
1.200
-16/-26
1.117
-2/-19
1.110
+17/-8