Columbia P5 User manual

Owner and Operator Manual
P5
P/N 712248-04 CPC P/N 99726-14 6/14

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

TABLE OF CONTENTS –P5
SECTION 1 INTRODUCTION PAGE
SAFETY MESSAGES .....................................................................................................................................1-1
VEHICLE IDENTIFICATION NUMBER –PERSONAL TRANSPORT VEHICLE ............................................1-1
VEHICLE IDENTIFICATION NUMBER –LOW SPEED VEHICLE..................................................................1-1
VIN MATRIX....................................................................................................................................................1-2
VEHICLE SPECIFICATIONS..........................................................................................................................1-2
SECTION 2 SAFETY
GETTING STARTED.......................................................................................................................................2-1
SAFETY GUIDELINES....................................................................................................................................2-1
SAFETY VEHICLE STATEMENTS.................................................................................................................2-1
BATTERY DISCONNECT METHOD...............................................................................................................2-2
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 PEDAL/PARKING BRAKE .................................................................................................................3-2
ACCELERATOR PEDAL.................................................................................................................................3-2
BATTERY STATE OF CHARGE METER........................................................................................................ 3-3
HOUR METER INDICATOR............................................................................................................................ 3-3
WARNING LABEL & OPERATING INSTRUCTIONS...................................................................................... 3-3
SYSTEM STATUS LIGHT...............................................................................................................................3-3
STEERING WHEEL........................................................................................................................................ 3-3
CHARGER RECEPTACLE & REMOTE LED..................................................................................................3-3
TURN SIGNAL/HAZARD WARNING SWITCH............................................................................................... 3-3
FUSE BLOCK –12V ELECTRICAL CIRCUIT.................................................................................................3-4
FUSE BLOCK –48V ELECTRICAL CIRCUIT.................................................................................................3-4
WINDSHIELD WIPER/WASHER .................................................................................................................... 3-4
MAINTENANCE ACCESS............................................................................................................................... 3-4
DRIVING THE VEHICLE.................................................................................................................................3-4
PRE-OPERATION CHECKLIST...................................................................................................................... 3-5
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.................................................................................................................................... 4-3
CHARGER OPERATING INSTRUCTIONS DELTA Q Charging System...................................................4-3
RED LIGHT CHARGER ERROR CODES DELTA Q Charging System..................................................... 4-4
CHECK / CHANGE CHARGING ALGORITHM DELTA Q Charging System ............................................. 4-5
BATTERY CHARGING PRO Charging System ...............................................................................4-5
TROUBLESHOOTING PRO Charging System....................................................................................4-6
LIGHT EMITTING DIODES (LED) FAULT CODE INDICATIONS PRO Charging System..............4-6
EXCESSIVELY DISCHARGED BATTERIES.................................................................................................. 4-7
SPECIFIC GRAVITY TEST.............................................................................................................................4-7
TIPS FOR PROLONGING BATTERY LIFE..................................................................................................... 4-8
BATTERY REMOVAL & INSTALLATION........................................................................................................4-8
SINGLE POINT BATTERY WATERING SYSTEM..........................................................................................4-8
SECTION 5 SERVICING YOUR VEHICLE
MAINTENANCE GUIDELINES........................................................................................................................ 5-1
MECHANICAL BRAKE SYSTEM.................................................................................................................... 5-1
TIRE CARE.....................................................................................................................................................5-1
WHEEL & TIRE REMOVAL/INSTALLATION..................................................................................................5-1
CLEANING......................................................................................................................................................5-1
MAINTENANCE SCHEDULE - OWNER/OPERATOR....................................................................................5-2
MAINTENANCE SCHEDULE - QUALIFIED TECHNICIAN.............................................................................5-2
VEHICLE TROUBLESHOOTING.................................................................................................................... 5-3
CONTROLLER TROUBLESHOOTING...........................................................................................................5-3
ii

TABLE OF CONTENTS –P5
SECTION 6 TOWING & TRANSPORTING
TOWING YOUR VEHICLE.............................................................................................................................. 6-1
TRANSPORTING YOUR VEHICLE ................................................................................................................6-1
SECTION 7 VEHICLE STORAGE
BATTERY PREPARATION............................................................................................................................. 7-1
VEHICLE PREPARATION ..............................................................................................................................7-1
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
10/24/13
Issued
TS
3/20/14
Added wiper/washer
TS
6/25/14
Added PRO Charging System
TS
iii

SECTION 1 INTRODUCTION
P5 OWNERS MANUAL 2013
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 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 2. Access to this location is by removing the three screws holding the cover in place. Another
location is in the glove box (Figure 3).
VIN
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 2).
The VIN is also noted on the LSV Vin Label (Figure 4) affixed to the
bottom of the front hood area.
Figure 2
Figure 1
Figure 3
Figure 4
1-1

SECTION 1 INTRODUCTION
P5 OWNERS MANUAL 2013
VIN MATRIX Personal Transport Vehicle (PVT)
VIN MATRIX low Speed Vehicle (LSV)
Digit 1 thru 3:
5FC = CPC
Manufacturer Identification
Digit 4: Line
L = Low Speed Vehicle
Digit 5: Series
L = P5
Digit 6: Body Type
2 = 2 Person
Digit 7: Engine Type
6 =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
D = 2013
E = 2014 etc.
Digit 11: Plant Location
1 = Reedsburg
Digit 12-17: Sequential Numbers
00019 - 000999
VEHICLE SPECIFICATIONS
ITEM
SPECIFICATION
ITEM
SPECIFICATION
Motor
48 volt, 15.3 hp @ 1750 rpm
Steering
Automotive rack and pinion.
Drive
Direct coupled to oil bath, helical
geared, rear axle
Tire PSI
32 psi 215/50-13
30 psi 205/50-10
Rear Axle
10.35.1 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
mechanical drum on rear
wheels, foot operated parking
brake. .
Digit 1 thru 3 = Abbreviation (Model)
P5P
Digit 4 = Power System
F = Sep Ex Regen (ACEplus)
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
5 = 500 Amp
Digit 8 = Brake System
Z = Rear Mechanical
Y = Rear Hydraulic
X = Front & Rear Hydraulic
Digit 9 = Build Year
L = 2012, M = 2013, N = 2014 etc.
Digit 10 Thru 13 –Build Sequence
1234
1-2

SECTION 1 INTRODUCTION
P5 OWNERS MANUAL 2013
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

SECTION 1 INTRODUCTION
P5 OWNERS MANUAL 2013
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 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 2. Access to this location is by removing the three screws holding the cover in place. Another
location is in the glove box (Figure 3).
VIN
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 2).
The VIN is also noted on the LSV Vin Label (Figure 4) affixed to the
bottom of the driver’s seat.
Figure 2
Figure 1
Figure 3
Figure 4
1-1

SECTION 1 INTRODUCTION
P5 OWNERS MANUAL 2013
VIN MATRIX Personal Transport Vehicle (PVT)
VIN MATRIX low Speed Vehicle (LSV)
Digit 1 thru 3:
5FC = CPC
Manufacturer Identification
Digit 4: Line
L = Low Speed Vehicle
Digit 5: Series
L = P5
Digit 6: Body Type
2 = 2 Person
Digit 7: Engine Type
6 =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
D = 2013
E = 2014 etc.
Digit 11: Plant Location
1 = Reedsburg
Digit 12-17: Sequential Numbers
00019 - 000999
VEHICLE SPECIFICATIONS
ITEM
SPECIFICATION
ITEM
SPECIFICATION
Motor
48 volt, 15.3 hp @ 1750 rpm
Steering
Automotive rack and pinion.
Drive
Direct coupled to oil bath, helical
geared, rear axle
Tire PSI
32 psi 215/50-13
30 psi 205/50-10
Rear Axle
10.35.1 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
mechanical drum on rear
wheels, foot operated parking
brake. .
Digit 1 thru 3 = Abbreviation (Model)
P5P
Digit 4 = Power System
F = Sep Ex Regen (ACEplus)
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
5 = 500 Amp
Digit 8 = Brake System
Z = Rear Mechanical
Y = Rear Hydraulic
X = Front & Rear Hydraulic
Digit 9 = Build Year
L = 2012, M = 2013, N = 2014 etc.
Digit 10 Thru 13 –Build Sequence
1234
1-2

SECTION 2 SAFETY
P5 OWNERS MANUAL 2013
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.
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.
2-1