Columbia SU5 User manual

Owner and Operator Manual
SU5
P/N 712307 CPC P/N 99727-14 2014
Find replacement parts for your cart faster at CartPros.com

Preface
Welcome, and congratulations on your choice of vehicle from Columbia ParCar Corp.! Your
vehicle has been manufactured in full compliance with all applicable American National
Standards Institute (ANSI) standards. Your safe use and operation of your vehicle is important
to us. Any alteration of your Columbia ParCar vehicle that results in the vehicle being in
noncompliance with applicable ANSI standards is strictly prohibited. Columbia ParCar 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.
Personal Transport Vehicles (PTV) 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.
Low Speed Vehicles (LSV) commonly referred to as NEV or Neighborhood Electric Vehicles
meet the requirements of the National Highway Traffic & Safety Administration (NHTSA) as
stated in the Code of Federal Regulations, Title 49, Part 571, Standard 500, Low Speed
Vehicles.
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
i
Find replacement parts for your cart faster at CartPros.com

TABLE OF CONTENTS –SU5
SECTION 1 INTRODUCTION PAGE
SAFETY MESSAGES .....................................................................................................1-1
VEHICLE IDENTIFICATION NUMBER –PERSONAL TRANSPORT VEHICLE..............1-1
VEHICLE IDENTIFICATION NUMBER –LOW SPEED VEHICLE...................................1-2
VIN MATRIX Personal Transport Vehicle (PVT)..............................................................1-2
VIN MATRIX Low Speed Vehicle (LSV) ..........................................................................1-3
VEHICLE SPECIFICATIONS ..........................................................................................1-3
SECTION 2 SAFETY
GETTING STARTED.......................................................................................................2-1
SAFETY GUIDELINES....................................................................................................2-1
SAFETY VEHICLE STATEMENTS .................................................................................2-1
BATTERY DISCONNECT METHOD...............................................................................2-3
SECTION 3 OPERATIONS AND CONTROLS
IMPORTANT FIRST STEP..............................................................................................3-1
INSPECTING THE VEHICLE..........................................................................................3-1
VEHICLE CONTROLS....................................................................................................3-2
KEYSWITCH...................................................................................................................3-2
DIRECTION SELECTOR ................................................................................................3-2
TURN SIGNAL/LIGHTS/HORN SWITCH........................................................................3-2
BRAKE, ACCELERATOR and PARKING BRAKE...........................................................3-3
MULTI-FUNCTION CLEARVIEW DISPLAY PANEL........................................................3-3
WARNING LABEL & OPERATING INSTRUCTIONS ......................................................3-4
STEERING WHEEL........................................................................................................3-4
CHARGER RECEPTACLE & REMOTE LED ..................................................................3-4
HAZARD WARNING SWITCH ........................................................................................3-5
FUSE BLOCK –12V ELECTRICAL CIRCUIT .................................................................3-5
FUSE BLOCK –48V ELECTRICAL CIRCUIT .................................................................3-5
WINDSHIELD WIPER/WASHER.....................................................................................3-5
TILT BED ........................................................................................................................3-6
SECOND SEAT...............................................................................................................3-6
BATTERY ACCESS........................................................................................................3-6
DRIVING THE VEHICLE.................................................................................................3-6
PRE-OPERATION CHECKLIST......................................................................................3-7
SECTION 4 ELECTRIC SYSTEM
IMPORTANT INFORMATION .........................................................................................4-1
BATTERY INSPECTION & MAINTENANCE...................................................................4-2
BATTERY CLEANING.....................................................................................................4-3
CONDITIONS WHICH AFFECT CHARGING..................................................................4-3
BATTERY CHARGING....................................................................................................4-4
CHARGER OPERATING INSTRUCTIONS.....................................................................4-4
RED LIGHT CHARGER ERROR CODES.......................................................................4-5
CHECK / CHANGE CHARGING ALGORITHM................................................................4-6
EXCESSIVELY DISCHARGED BATTERIES ..................................................................4-6
SPECIFIC GRAVITY TEST.............................................................................................4-7
TIPS FOR PROLONGING BATTERY LIFE.....................................................................4-7
BATTERY REMOVAL & INSTALLATION........................................................................4-8
SINGLE POINT BATTERY WATERING SYSTEM ..........................................................4-8
ii
Find replacement parts for your cart faster at CartPros.com

SECTION 5 SERVICING YOUR VEHICLE
MAINTENANCE GUIDELINES........................................................................................5-1
BRAKE SYSTEM ............................................................................................................5-1
BRAKE FLUID MAINTENANCE......................................................................................5-1
TIRE CARE.....................................................................................................................5-1
WHEEL & TIRE REMOVAL/INSTALLATION...................................................................5-1
CLEANING......................................................................................................................5-2
MAINTENANCE SCHEDULE - OWNER/OPERATOR.....................................................5-2
MAINTENANCE SCHEDULE - QUALIFIED TECHNICIAN..............................................5-2
VEHICLE TROUBLESHOOTING ....................................................................................5-3
CONTROLLER TROUBLESHOOTING ...........................................................................5-3
SECTION 6 TOWING & TRANSPORTING
TOWING YOUR VEHICLE..............................................................................................6-1
TRANSPORTING YOUR VEHICLE.................................................................................6-1
SECTION 7 VEHICLE STORAGE
BATTERY PREPARATION .............................................................................................7-1
VEHICLE PREPARATION ..............................................................................................7-2
RETURNING VEHICLE TO SERVICE ............................................................................7-2
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
5/1/14
Issued
TS
iii
Find replacement parts for your cart faster at CartPros.com

SECTION 1 INTRODUCTION
SU5 OWNERS MANUAL 2014
This manual provides important safety information, operating instructions, model specifications
and maintenance instructions for electric vehicles. It should be read completely before
attempting to drive or service the vehicle. Failure to follow the instructions in this manual could
result in property damage, severe personal injury, or death.
The information in this manual is limited to care and maintenance information only. Information
covering repairs is provided in detailed service manuals available from Columbia Dealers. Such
major repairs 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.
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.
VEHICLE IDENTIFICATION NUMBER –PERSONAL TRANSPORT VEHICLES (PTV)
Each PTV vehicle contains a unique Vehicle Identification Number (VIN) label. The VIN
describes facts and features of the vehicle and contains thirteen (13) digits. Figure 1-1 is an
example of a VIN label.
VIN labels and can be found in several locations on the vehicle. One location will be under the
steering wheel cover as shown in Figure 1-2. Access to this location is by removing the three
screws holding the cover in place. A nameplate is located in the front hood compartment and
has important information such as model, vehicle weights and rated capacity (load, operator and
passenger). Do not exceed this rated capacity. Read carefully.
VIN
Figure 1-2
Figure 1-1
1-1
Find replacement parts for your cart faster at CartPros.com

SECTION 1 INTRODUCTION
SU5 OWNERS MANUAL 2014
VEHICLE IDENTIFICATION NUMBER LOW SPEED VEHICLES (LSV).
The VIN is printed on a white label, affixed to the top
of the dash and affixed to the steering wheel under
the steering wheel cover (Figure 1-2). The VIN is
also noted on the LSV Vin Label (Figure 1-3) affixed
to the bottom of the front hood area.
VIN MATRIX Personal Transport Vehicle (PVT)
Digit 1 thru 3 = Abbreviation (Model)
S5S (Short), S5L (Long)
Digit 4 = Power System
F = Sep Ex Regen (ACEplus)
G = AC Drive, Induction Motor
Digit 5 = System Voltage
4 = 48V (8 –6V)
M = AGM (8 -6V)
Digit 6 = VIN Spacer
- = Standard
# = Special Product
Digit 7= Controller Amperage
4 = 400 Amp
B = 450 Amp
5 = 500 amp
Digit 8 = Brake System
V =Front & Rear Mechanical
Digit 9 = Build Year
N = 2014, P = 2015, etc.
Digit 10 Thru 13 –Build Sequence
1234
Figure 1-3
1-2
Find replacement parts for your cart faster at CartPros.com

SECTION 1 INTRODUCTION
SU5 OWNERS MANUAL 2014
VIN MATRIX low Speed Vehicle (LSV)
Digit 1 thru 3:
5FC = CPC
Manufacturer Identification
Digit 4: Line
L = Low Speed Vehicle
Digit 5: Series
S = Summit
Digit 6: Body Type
2 = 2 Person
4 = 4 person
Digit 7: Engine Type
6 =DC Power System
8 = AC Power System
Digit 8: Restraint
A = Type 1 Seat Belt
Assembly
B = Type 2 Seat Belt
Assembly (3 Point)
Digit 9: Check Digit
Calculated per 49CFR 565.4
Digit 10: Model Year
E = 2014
F = 2015 etc.
Digit 11: Plant Location
1 = Reedsburg
Digit 12-17: Sequential Numbers
00019 - 000999
VEHICLE SPECIFICATIONS
ITEM
SPECIFICATION
ITEM
SPECIFICATION
Motor
5 KW AC
Steering
Automotive rack and pinion.
Drive
Direct coupled to oil bath,
helical geared, rear axle
Tire PSI
32 psi
Rear Axle
16.77:1 helical gear reduction
with integral differential
Battery
Deep
Cycle
48 Volt: 8 - 6 volt, heavy
duty, 225 Ah
Charger
Built in, micro-processor
control, fully sealed, anti-drive
away interlock, 110-240 V
AC, 50/60 Hz
Speed
Control
Programmable, solid state,
reduced speed reverse with
diagnostic LED and
calibrator interface
Directional
Control
Safety Directional Keyswitch
with FL, FH (forward), R
(reverse) and N (neutral)
Brakes
Spring applied, auto-
adjusting hydraulic drum on
rear wheels, front disc, foot
operated parking brake.
NOTICE: Always provide the complete VIN when contacting your dealer for technical
assistance or maintenance and repair parts.
For your own personal reference, fill in the VIN in the space provided below:
1-3
Find replacement parts for your cart faster at CartPros.com

SECTION 2 SAFETY
SU5 OWNERS MANUAL 2014
GETTING STARTED
For personal safety before operating the vehicle, it is the operator’s responsibility to read,
understand and follow the basic rules of operation and maintenance instructions in this manual.
If you are responsible for the use of the vehicle, it is your responsibility to inform the person or
persons using the vehicle about the following basic rules of operation for their personal safety.
It is Columbia ParCar Corp’s specific recommendation that the following warnings must be
observed at all times. Not all are repeated throughout this manual, but the recommendations
included must be observed whenever these subjects (vehicle operation hazards, battery
hazards, etc.) are encountered.
Be a safe operator. Electric vehicles are only as safe as the person who is at the controls. If
accidents are to be prevented, and they most certainly can be prevented, operators must accept
their full measure of responsibility. While the designer, the manufacturer and the safety engineer
can help minimize the possibility of an accident, their combined efforts can be erased by a
single careless act.
SAFETY GUIDELINES
Observe the following guidelines for safe operation.
Define where vehicles may be driven.
Define who should be allowed to drive the vehicle.
Instruct first-time drivers.
Maintain vehicles in a safe driving condition.
Enforce safe-driving rules.
SAFETY VEHICLE STATEMENTS
This vehicle will not provide protection from lightning, flying objects, or other storm
related hazards. If driving the vehicle in a storm, leave the vehicle and take shelter as
per safety guidelines for your location.
Any modifications or changes to the vehicle that affect the stability, steering or that
results in increased speed beyond factory specifications could result in vehicle
damage, severe personal injury or death.
When replacement parts are required, use only genuine Columbia vehicle parts.
No modifications or additions, which affect the mechanical or electrical integrity and
the safe operation of the unit, shall be made without the written approval of the
manufacturer. If in doubt about any modification, contact your local Columbia Dealer
or Columbia ParCar Customer Service.
2-1
Find replacement parts for your cart faster at CartPros.com

SECTION 2 SAFETY
SU5 OWNERS MANUAL 2014
Follow all procedures exactly and observe all safety messages stated in this manual.
Working on vehicles without following proper procedures and using proper equipment
may result in vehicle damage or personal injury.
Do not attempt to service hot motor or components. Failure to observe this warning
could result in severe burns.
Always wear safety glasses or approved eye protection while servicing vehicle.
Failure to maintain vehicle properly could result in decreased vehicle performance,
reliability or cause severe personal injury.
If any problems are found during scheduled maintenance or inspections, do not
operate vehicle until repairs are made.
For personal safety and to maintain stability and control, operate this vehicle under
these conditions only. Failure to comply with these warnings may result in bodily
injury and property damage.
All vehicles should be operated from the driver’s side by authorized persons.
Never exceed the capacity ratings of the vehicle. Exceeding these limits may endanger
occupants.
Personal injury may result if body parts (arms, head, and legs) are not kept inside
vehicle while moving.
Do not start moving until all occupants are seated. Remain seated and hold on while
vehicle is in motion.
Before leaving your seat, completely stop vehicle and lock parking brake. If vehicle is
to be left unattended, turn keyswitch to “OFF” and remove key.
Do not use accelerator to hold vehicle on an incline. Use brake.
Make sure directional switch is in position for the desired direction of travel before
depressing the accelerator. Do not change the directional switch while vehicle is
moving.
Drive slowly in turns and up and down grades. Do not make turns on steep hills or
inclines.
Do not operate while under the influence of alcohol or drugs.
Personal Transportation Vehicles are not Federal or State DOT approved and are not
equipped to be operated on public roads or highways.
To avoid the risk of injury or vehicle damage, operate at maximum speed only on
smooth flat surfaces.
Allow additional stopping distance when traveling at higher speeds.
2-2
Find replacement parts for your cart faster at CartPros.com

SECTION 2 SAFETY
SU5 OWNERS MANUAL 2014
These basic rules of operation, combined with courtesy and common sense, will help make
driving your Columbia vehicle a safe and pleasant experience.
BATTERY DISCONNECT METHOD Figure 2-1
Batteries are located under the front seats. Before performing any vehicle service, power down
the vehicle using the blue quick disconnect (arrow).
Figure 2-1
2-3
Find replacement parts for your cart faster at CartPros.com