Columbia EX-21 EXPEDITER User manual

Owner
and
Operator
Manual
EX-21 EXPEDITER
Electric Vehicles
P/N 709447-04

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 - 2986162,
2987934, 3116089, 3144631, 3144860, 3229792, 3434887, 3559773, 3673359, 3680403,
3683716, 3709317, 4648473, Des. 225626.
1115 Commercial Avenue • Reedsburg, WI 53959
Phone: [phone] • Fax: [phone]
[phone] • Web: www.parcar.com
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TABLE OF CONTENTS
1.0 INTRODUCTION
1.1 SAFETY MESSAGES
1.2 VEHICLE DESCRIPTION
1.3 VEHICLE IDENTIFICATION NUMBER (VIN)
1.4 VIN MATRIX
1.5 VEHICLE SPECIFICATIONS
2.0 SAFETY
2.1 GETTING STARTED
2.2 SAFETY VEHICLE STATEMENTS
2.3 SAFETY WARNINGS
2.4 SAFETY CONCERNS
3.0 OPERATIONS AND CONTROLS
3.1 IMPORTANT FIRST STEP
3.2 INSPECTING THE VEHICLE
3.3 VEHICLE CONTROLS
3.3.4 HORN BUTTON
3.3.1 POWER KEYSWITCH
3.3.2 DIRECTION SELECTOR
3.3.3 SYSTEM STATUS LIGHT
3.3.4 HORN BUTTON
3.3.5 LIGHT SWITCH
3.3.6 BATTERY STATE OF CHARGE METER
3.3.7 HOUR METER INDICATOR
3.3.8 OPERATING INSTRUCTIONS
3.3.9 ACCELERATOR PEDAL
3.3.10 BRAKE PEDAL/PARKING BRAKE
3.3.11 WARNING LABEL
3.3.12 CHARGER RECEPTACLE
3.3.13 BACKREST/REAR PASSENGER SEAT
3.3.14 STEERING WHEEL/HANDLE/TILLER
3.3.15 SEAT SWITCH/TRACTION INTERLOCK
3.4 VEHICLE OPERATING INSTRUCTIONS
3.4.1 DRIVING THE VEHICLE
3.4.2 PRE-OPERATION CHECKLIST
4.0 ELECTRIC SYSTEM
4.1 IMPORTANT INFORMATION
4.2 BATTERY INSPECTION & MAINTENANCE
4.3 BATTERY CLEANING
4.4 CONDITIONS WHICH AFFECT CHARGING
4.5 DELTA-Q BATTERY CHARGING
4.5.1 CHARGER OPERATING INSTRUCTIONS
4.5.2 RED LIGHT CHARGER ERROR CODES
4.5.3 CHECK / CHANGE CHARGING ALGORITHM
4.6 EXCESSIVELY DISCHARGED BATTERIES
4.7 SPECIFIC GRAVITY TEST
4.8 TIPS FOR MAINTAINING YOUR BATTERIES
4.9 BATTERY DISCONNECT METHODS
4.10 BATTERY REMOVAL & INSTALLATION
4.10.1 24 VOLT SYSTEM
4.10.2 48 VOLT SYSTEM
4.11 SINGLE POINT BATTERY WATERING SYSTEM
5.0 SERVICING YOUR VEHICLE
5.1 MAINTENANCE GUIDELINES
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5.2 MECHANICAL BRAKE SYSTEM
5.3 TIRE CARE
5.4 WHEEL & TIRE REMOVAL/INSTALLATION
5.5 CLEANING
5.6 LUBRICATION
5.7 MAINTENANCE SCHEDULE - OWNER/OPERATOR
5.8 MAINTENANCE SCHEDULE - QUALIFIED TECHNICIAN
5.9 VEHICLE TROUBLESHOOTING
5.10 CONTROLLER TROUBLESHOOTING
6.0 TOWING & TRANSPORTING
6.1 TOWING
6.2 TRANSPORTING YOUR VEHICLE
7.0 VEHICLE STORAGE
7.1 BATTERY PREPARATION
7.2 VEHICLE PREPARATION
7.3 RETURNING VEHICLE TO SERVICE
NOTICE:In an effort to streamline product support, please ensure your vehicle
is properly registered with Columbia ParCar. Registration allows for more
effective product support including product updates and warranty processing.
Please consult with your servicing dealer to verify or complete the registration
process.
CHANGE HISTORY
DATE
DESCRIPTION
BY
6/2008
Issued
TS
5/2011
Added above block
TS
7/12
Added remote Delta Q LED
TS
11/4/13
Corrected algorithm table
TS
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1.0 INTRODUCTION
This manual provides important safety information, operating instructions, model specifications and
maintenance instructions for Expediter vehicles.
The information in this manual is limited to care and maintenance information only. Information covering
repairs and technical service is provided in detailed service manuals available from Columbia Dealers.
These activities require the attention of a skilled technician and the use of special tools and equipment.
Your Columbia Dealer has the facilities, experience and genuine Columbia vehicle parts and accessories
to properly service Columbia vehicles.
1.1 SAFETY MESSAGES
Safety messages and other information in this manual are preceded by the words DANGER, WARNING,
CAUTION or NOTICE. They are printed in bold face, and are very important. We recommend you take
special notice of this information.
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.
1.2 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.
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).
1.3 VEHICLE IDENTIFICATION NUMBER (VIN)
Do not remove any nameplate, warnings, or instructions affixed to your Columbia Industrial
Vehicle. Promptly replace any that become damaged or removed.
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 in the right front corner of
the rear body chassis as shown in Figure 1.3.1. It is also on the vehicle nameplate located on the vertical
panel below the seat as shown in Figure 1.3.2.
1-1