Columbia Expediter EX-21 2017 User manual

PN 709447-05
7/2016
2017
Model
EX-21
Expediter
Owner and Operator Manual

Expediter EX-21
2017
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.
CHANGE HISTORY
DATE
DESCRIPTION
BY
7/1/2016
Issued 2017 Model Year
CPC
This manual provides important safety information, operating instructions, model specifications
and maintenance instructions for the EX 21 Expediter.
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.
1115 Commercial Avenue • Reedsburg, WI 53959
Phone: [phone] • Fax: [phone]
[phone] • Web: www.columbiausa.com

Expediter EX-21
Page 1
TABLE OF CONTENTS
INTRODUCTION PAGE
TABLE OF CONTENTS ..................................................................................................1
SAFETY MESSAGES .....................................................................................................2
VEHICLE DESCRIPTION................................................................................................3
VEHICLE IDENTIFICATION NUMBER LOCATION ........................................................3
VEHICLE IDENTIFICATION NUMBER DECODING........................................................4
VEHICLE SPECIFICATIONS ..........................................................................................4
SAFETY
GETTING STARTED.......................................................................................................5
SAFETY GUIDELINES....................................................................................................5
VEHICLE SAFETY STATEMENTS .................................................................................5
ADDITIONAL OPERATING SAFETY CONCERNS.........................................................7
OPERATIONS AND CONTROLS
IMPORTANT FIRST STEP..............................................................................................7
INSPECTING THE VEHICLE..........................................................................................8
WHAT TO DO IN EVENT OF A PROBLEM NOTICED DURING INSPECTION ..............8
VEHICLE CONTROLS....................................................................................................9
KEY SWITCH..................................................................................................................9
DIRECTION SELECTOR KNOB .....................................................................................9
SYSTEM STATUS LIGHT...............................................................................................9
LIGHT SWITCH...............................................................................................................9
BATTERY STATE OF CHARGE .....................................................................................9
HORN SWITCH...............................................................................................................9
OPERATING INSTRUCTION LABEL..............................................................................9
ACCELERATOR PEDAL.................................................................................................10
BRAKE PEDAL ...............................................................................................................10
OPERATOR WARNING LABEL......................................................................................10
ADDITIONAL INFORMATION LABEL.............................................................................10
PRE-OPERATION CHECKLIST......................................................................................11
DRIVING THE VEHICLE.................................................................................................12
BACKREST POSITION...................................................................................................12
STEERING THE VEHICLE..............................................................................................12
ELECTRIC SYSTEM
BATTERY INSPECTION & MAINTENANCE...................................................................14
BATTERY CLEANING.....................................................................................................15
CONDITIONS WHICH AFFECT CHARGING..................................................................16
BATTERY CHARGING SYSTEM....................................................................................17
CHARGER ERROR CODES...........................................................................................18
CHARGER INTERNAL ALGORITHM SETTING..............................................................19
EXCESSIVELY DISCHARGED BATTERIES ..................................................................20
BATTERY REMOVAL & INSTALLATION........................................................................20
TIPS FOR PROLONGING BATTERY LIFE.....................................................................21
SINGLE POINT WATERING SYSTEM............................................................................21

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SERVICING YOUR VEHICLE
MAINTENANCE SCHEDULE - OWNER/OPERATOR.....................................................22
MAINTENANCE SCHEDULE - QUALIFIED TECHNICIAN..............................................23
MAINTENANCE GUIDELINES........................................................................................23
LIFTING INSTRUCTIONS...............................................................................................23
BRAKE PEDAL ...............................................................................................................24
TIRE CARE/WHEEL REMOVAL .....................................................................................24
CLEANING......................................................................................................................25
LUBRICATION................................................................................................................25
VEHICLE TROUBLESHOOTING ....................................................................................25
CONTROLLER TROUBLESHOOTING ...........................................................................26
VEHICLE STORAGE
BATTERY PREPARATION .............................................................................................27
VEHICLE PREPARATION ..............................................................................................28
RETURNING VEHICLE TO SERVICE ............................................................................28
TOWING AND TRANSPORTING....................................................................................28
WARRANTY
WARRANTY INFORMATION..........................................................................................29
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.

Expediter EX-21
Page 3
VEHICLE DESCRIPTION
The Expediter is a single operator vehicle involving sit-down operation, with capacity for one
rear facing passenger. This vehicle is designed to be driven on smooth surfaces in and around
industrial plants, warehousing, institutions, motels, mobile home parks, and resorts.
This vehicle is not designed to be driven 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 1993 Part III).
VEHICLE IDENTIFICATION NUMBER (VIN)
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 can be found in two locations.
The VIN is recorded on the vehicle
nameplate which is located on the left
side of the operator’s position.
The VIN is also stamped on the metal
cross bar located under the rear deck
platform.
The nameplate also has other important
information such as vehicle weights and
capacity.
Do not exceed this capacity.
This rated capacity includes cargo and
operator.
To ensure prompt service when repairs or
adjustments are required, your Columbia
Dealer must have the VIN.
For your own personal reference, fill in the VIN in the space provided below:
____________________________________________
NOTICE: Always provide the complete VIN when contacting your dealer for technical
assistance or maintenance and repair parts.

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Page 4
VIN MATRIX - 13 DIGIT VIN
Digit 1 thru 3 = Abbreviation (Model)
ET2 = 3 Wheel, ET4 = 4 Wheel (EX21 - Expediter)
Digit 4 = Power System
E = Separately Excited Regenerative
Digit 5 = System Voltage
2 = 24V, 4 = 48V
Digit 6 = VIN Spacer
-= normal
# = Special Product
Digit 7= Controller Amperage
3 = 300A, 4 = 400A
Digit 8 = Axle/Brake System
Z = Rear Mechanical
Digit 9 = Build Year
Q = 2016, R = 2017, S = 2018 etc.
(Letters I & O not used)*
Digit 10 Thru 13 – Build Sequence
1234
VEHICLE SPECIFICATIONS
EX21 T 24
EX21 F 24
EX21 T 48
EX21 F 48
Passenger Capacity
One or Two
Max. Speed (mph)
8
Turning
Curb to Curb (in)
127 175 127 175
Turning Intersecting Aisle (in)
66
83
66
83
Ground Clearance (in)
4
Wheelbase (in)
52.5
53.5
52.5
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
Bed Height (in)
20.5
Tires
4.8x8, LRB (Recommend 50 psi.)
4.8x8 Foam Filled
4.0x8 Solid Non-marking
4.8x8, Non-marking (Recommend 50 psi.)

Expediter EX-21
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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.
Please be a safe operator. Electric vehicles are only as safe as the person who is at the
controls. If accidents are to be prevented, operators must accept their full measure of
responsibility. While the designer, the manufacturer, the dealer 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-operating rules.
VEHICLE SAFETY 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 result
in increased speed beyond factory specifications could result in vehicle damage,
severe personnel 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.

Expediter EX-21
Page 6
Only trained service professionals should repair or service this vehicle. Persons doing
even simple repairs or maintenance should have working knowledge and experience in
general electrical and mechanical repair.
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.
Moving parts hazard! When operating any vehicle in a stationary position, avoid
components which could snag clothing or cause severe injury to body parts. A running
vehicle must be worked on with the greatest care.
Failure to maintain vehicle properly could result in decreased vehicle performance,
reliability or cause severe personal injury.
Always wear safety glasses or approved eye protection while performing vehicle
maintenance.
This vehicle is not Federal or State DOT approved and is not equipped to be operated
on public roads or highways.
Do not exceed the rated vehicle speed. Exceeding this speed may result in steering
difficulty, motor damage, and/or loss of control and injury.
Never exceed the capacity ratings of the vehicle. Exceeding these limits may endanger
occupant or cause vehicle damage.
Completely stop vehicle before stepping off.
If vehicle is to be left unattended, turn keyswitch to “OFF” and remove key.
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.
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.
Do not drive this vehicle in hazardous areas unless this vehicle is approved and
labeled for such operation.

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Page 7
ADDITIONAL OPERATION SAFETY CONCERNS
It is recommended that the operator and owner or renter of this vehicle comply with the OSHA
requirements as stated in the Code of Federal Regulations, Section 29, 1910.178, Powered
Industrial Truck Training Standard and the ANSI requirements as stated in Personnel and
Burden Carriers ANSI B56.8.
As a minimum every operator should, in addition to the above requirements found in the
standards noted above:
Demonstrate a working knowledge of each control.
Understand all safety rules and guidelines as presented in this manual.
Know how to properly load and unload cargo.
Know how to properly park the vehicle.
Recognize an improperly maintained vehicle.
Demonstrate ability to handle the vehicle in all conditions.
Every owner or renter of this vehicle must, at a minimum:
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.
Install safety signage concerning hills, speed bumps, ramps, turns, blind crossings,
intersections, etc.
Define who should and who should not drive the vehicles.
Enforce 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 and maintain a schedule for daily, weekly,
monthly, quarterly, semi-annually and annual vehicle inspections.
Determine who, when, and how should pre-operation inspections be conducted.
Notify operators what should be done if an unsafe condition or operating problem is
discovered.
IMPORTANT FIRST STEP
Upon initial delivery, it is very important that the battery pack is properly charged. This is
required if the vehicle is to be stored for later use or is to be used immediately.
Check that the batteries are not damaged or leaking and that connections are tight.
NOTICE: The following information does NOT apply to sealed batteries.
Remove the battery vent caps and inspect each cell for proper electrolyte level. The battery
manifold assemblies on vehicles with a single point watering system will require a ¼
counterclockwise turn to be removed for this inspection.
If the electrolyte level is below the plates add only enough water to cover the plates.
NOTICE: Do not overfill a cell. Electrolyte expands and can overflow during charging.
With the electrolyte level correct, use the on board charger to charge the batteries.
Charging is complete when the remote LED is steady green.
Vehicles without a single point watering system, after charging, refill cells to below the
bottom of each cell vent.

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INSPECTING THE VEHICLE
Upon receipt of vehicle, perform a pre-delivery inspection of the vehicle. Also, before using the
vehicle, there are checks that must be performed to ensure that it is in safe proper working
order.
NOTICE: Vehicle should be inspected immediately after delivery. Use the following
guidelines to make sure there are no obvious problems.
Examine the contents of all packages and accessories that may have come in separate
packages with this vehicle. Make sure everything listed on the packing slip is there. Items
should not be broken or damaged.
Examine any visible wiring for obvious signs of damage. Check that all connections are secure.
Check that battery connections are tight and all cells are filled to above plates. Check for
damaged or leaking batteries.
Inspect the tires for obvious wear or damage. Check for proper tire inflation. Refer to
manufactures recommendation imprinted on tire sidewall. Make sure that all wheel lugs are
secure.
Check the body and other parts for obvious damage. Look for body damage, jagged edges etc.
that may cause personal injury.
Operate each of the following controls before turning on the power keyswitch.
Accelerator and Brake Pedals
Steering Wheel, Handle Bar or Tiller Bar
NOTICE: Each control should operate smoothly and easily without sticking or
requiring excessive effort.
Check that the horn sounds and that the key can only be removed when keyswitch is in the
“OFF” position.
WHAT TO DO IF YOU HAVE A PROBLEM
If vehicle has just been delivered, report any physical damage or missing items to the shipping
company and your local Columbia Dealer.
Report any service issue problems to the individual(s) responsible for correction and/or repair or
contact your local Columbia Dealer for service.
If any problems are found, Do not operate vehicle until repairs are made. Failure to
make necessary repairs could result in fire, severe personal injury, property damage
or death. Consult your local Columbia Dealer for professional service.