Columbia SU5-S/L-2 User manual

PN 712420-00
3/2017
2017
Model
SU5-S/L-2
Summit
Utilitruck
Owner and Operator Manual

SU5-S/L
Page 1
Preface
Welcome, and congratulations on your choice of vehicle from Columbia! 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 vehicle that results in the vehicle being in noncompliance with applicable ANSI
standards is strictly prohibited. Columbia 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 the material contained herein is accurate as of the date this
publication was approved for printing. Columbia 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 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.
Columbia 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
3/17/2017
Issued
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.
1115 Commercial Ave • Reedsburg, WI 53959
Phone: [phone] • [phone] • Web: www.ColumbiaUSA.com

SU5-S/L
Page 2
TABLE OF CONTENTS –SU5
INTRODUCTION PAGE
SAFETY MESSAGES .....................................................................................................3
VEHICLE IDENTIFICATION NUMBER –PERSONAL TRANSPORT VEHICLE..............4
VEHICLE IDENTIFICATION NUMBER –LOW SPEED VEHICLE...................................5
VEHICLE SPECIFICATIONS ..........................................................................................6
SAFETY
GETTING STARTED.......................................................................................................7
SAFETY GUIDELINES....................................................................................................7
SAFETY VEHICLE STATEMENTS .................................................................................7
OPERATIONS AND CONTROLS
IMPORTANT FIRST STEP..............................................................................................9
INSPECTING THE VEHICLE..........................................................................................9
VEHICLE CONTROLS....................................................................................................10
KEYSWITCH...................................................................................................................10
DIRECTION SELECTOR ................................................................................................10
TURN SIGNAL/LIGHTS/HORN SWITCH........................................................................11
WINDSHIELD WIPER/WASHER.....................................................................................11
PARKING BRAKE...........................................................................................................11
STEERING WHEEL........................................................................................................12
HAZARD WARNING SWITCH ........................................................................................12
FUSE BLOCK –12V ELECTRICAL CIRCUIT .................................................................12
FUSE BLOCK –48V ELECTRICAL CIRCUIT .................................................................12
TILT BED ........................................................................................................................13
SECOND SEAT...............................................................................................................13
SECTION 4 ELECTRIC SYSTEM
BATTERY ACCESS........................................................................................................13
IMPORTANT INFORMATION .........................................................................................13
MULTI-FUNCTION CLEARVIEW DISPLAY PANEL........................................................14
MULTI-FUNCTION SMARTVIEW DISPLAY PANEL.......................................................16
WARNING LABEL & OPERATING INSTRUCTIONS ......................................................16
DRIVING THE VEHICLE.................................................................................................16
PRE-OPERATION CHECKLIST......................................................................................17
BATTERY INSPECTION & MAINTENANCE...................................................................18
BATTERY CLEANING.....................................................................................................20
CONDITIONS WHICH AFFECT CHARGING..................................................................21
BATTERY CHARGING....................................................................................................21
CHARGER OPERATING INSTRUCTIONS.....................................................................22
VEHICLE LOCKOUT/SAFETY INTERLOCK...................................................................23
CHARGER LED CODES.................................................................................................24
EXCESSIVELY DISCHARGED BATTERIES ..................................................................25
TIPS FOR PROLONGING BATTERY LIFE.....................................................................25
PROPER CARE OF DEEP CYCLE BATTERIES ............................................................26
BATTERY REMOVAL & INSTALLATION........................................................................27
SINGLE POINT BATTERY WATERING SYSTEM ..........................................................27

SU5-S/L
Page 3
SERVICING YOUR VEHICLE
MAINTENANCE GUIDELINES........................................................................................28
BRAKE SYSTEM ............................................................................................................28
BRAKE FLUID MAINTENANCE......................................................................................28
TIRE CARE.....................................................................................................................28
WHEEL & TIRE REMOVAL/INSTALLATION...................................................................28
CLEANING......................................................................................................................29
MAINTENANCE SCHEDULE - OWNER/OPERATOR.....................................................30
MAINTENANCE SCHEDULE - QUALIFIED TECHNICIAN..............................................30
VEHICLE TROUBLESHOOTING ....................................................................................30
CONTROLLER TROUBLESHOOTING ...........................................................................30
SMARTVIEW DISPLAY FAULT CODES.........................................................................31
TOWING & TRANSPORTING
TOWING YOUR VEHICLE..............................................................................................33
TRANSPORTING YOUR VEHICLE.................................................................................33
VEHICLE STORAGE
BATTERY PREPARATION .............................................................................................34
VEHICLE PREPARATION ..............................................................................................35
RETURNING VEHICLE TO SERVICE ............................................................................35
WARRANTY
LIMITED WARRANTY COVERAGE................................................................................36
RECORD OF SERVICE HISTORY AND DEALER CONTACT INFORMATION ..............38
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.

SU5-S/L
Page 4
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 on the top of the dash panel on the driver’s side or 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 also located in the front hood compartment and has important
information such as model, vehicle weights and rated capacity (load, operator and passenger)
as shown in Figure 1-3. Do not exceed this rated capacity.
Figure 1-1 Figure 1-2 Figure 1-3
VIN MATRIX Personal Transport Vehicle (PVT)
Digit 1 thru 3 = Abbreviation (Model)
S7S (Short), S7L (Long)
Digit 4 = Power System
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
2 = 275 Amp
B = 450 Amp
D = 650 amp
Digit 8 = Brake System
V/R = HD F/R Hydraulic
Digit 9 = Build Year
R = 2017, S = 2018, etc.
Digit 10 Thru 13 –Build Sequence
ie…1234

SU5-S/L
Page 5
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 low Speed Vehicle (LSV)
Digit 1 thru 3:
5FC = CPC
Manufacturer Identification
Digit 4: Line
L = Low Speed Vehicle
Digit 5: Series
L = Utilitruck
Digit 6: Body Type
2 = 2 Person
4 = 4 person
Digit 7: Engine Type
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
H = 2017
J = 2018
Digit 11: Plant Location
1 = Reedsburg
Digit 12-17: Sequential Numbers
00001 - 009999

SU5-S/L
Page 6
VEHICLE SPECIFICATIONS
ITEM
SPECIFICATION
Battery Type:
Deep Cycle
48 Volt: 8 - 6 volt, heavy duty, 225 Ah minimum.
Brakes
Spring applied, auto-adjusting hydraulic drum on rear wheels,
front disc, electric motor parking brake.
Charger
Built in, micro-processor control, fully sealed, anti-drive away
interlock, 100-230 V AC, 50/60 Hz.
Directional Control
Rotary directional switch with FL (forward low), FH (forward
high), R (reverse) and N (neutral).
Drive
Direct coupled to oil bath, helical geared.
Motor
5 KW or 8 KW AC Brushless.
Rear Axle
10.37:1 or 16.77:1 helical gear reduction with integral
differential.
Speed Controller
Programmable, solid state, reduced speed reverse with
diagnostic interface and display panel.
Steering
Automotive type rack and pinion.
Tire PSI
32 psi
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.

SU5-S/L
Page 7
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 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-driving 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 Customer Service.

SU5-S/L
Page 8
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. These basic rules of operation, combined with courtesy
and common sense, will help make driving your Columbia vehicle a safe and pleasant
experience.
All vehicles should only 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 engage 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, instead use service brake pedal.
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 or 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.
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.

SU5-S/L
Page 9
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.
Vehicles with a single point watering system will require completion of 4 to 5 charge cycles
before watering.
NOTICE: If the vehicle is not going to be used the charger can remain connected to an
AC source. It has the capability to test and recharge the battery pack during storage.
INSPECTING THE VEHICLE
After battery charging, perform an inspection of the vehicle to ensure that it is in safe proper
working order.
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.
Inspect the tires for obvious wear or damage. Check for proper tire inflation (32 psi
recommended). Make sure that all wheel lugs are secure.
Check the body, seats, trim and other external 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 Pedal for smooth operation.
Braking Pedal, assure presence of a firm pedal with minimal travel.
Check steering for responsiveness and minimal play.
Key can only be removed when keyswitch is in the “OFF” position.