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Columbia EX-21 EXPEDITER Owner's And Operator's Manual

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

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  • Page 1 Owner Operator Manual EX-21 EXPEDITER Electric Vehicles P/N 709447-04...
  • Page 2 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.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS INTRODUCTION SAFETY MESSAGES VEHICLE DESCRIPTION VEHICLE IDENTIFICATION NUMBER (VIN) VIN MATRIX VEHICLE SPECIFICATIONS SAFETY GETTING STARTED SAFETY VEHICLE STATEMENTS SAFETY WARNINGS SAFETY CONCERNS OPERATIONS AND CONTROLS IMPORTANT FIRST STEP INSPECTING THE VEHICLE VEHICLE CONTROLS 3.3.4 HORN BUTTON 3.3.1 POWER KEYSWITCH 3.3.2...
  • Page 4 VEHICLE PREPARATION 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.

  • Page 5: Introduction

    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.

  • Page 6: Vehicle Specifications

    The nameplate has important information such as model, vehicle weights and rated capacity (load, operator and passenger). Do not exceed this rated capacity. Read carefully. To ensure prompt service when repairs or adjustments are required, your Columbia Dealer must have the VIN. ET2C2-3ZG1234 is an example of a current VIN.

  • Page 7: Safety

    Columbia ParCar Corporation’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 (indoor vehicle operation hazards, battery hazards, etc.) are...

  • Page 8: Safety Concerns

    When replacement parts are required, use only genuine Columbia Industrial & Commercial Vehicle parts. No modifications or additions, which affect the mechanical or electrical integrity and the safe operation of the vehicle, shall be made without the written approval of the manufacturer. If such modifications are approved, the capacity, operation, and maintenance instruction markings shall be changed accordingly.
  • Page 9 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.

  • Page 10: Operations And Controls

    3.0 OPERATIONS AND CONTROLS 3.1 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. ...

  • Page 11: Vehicle Controls

    Columbia Dealer. Report any battery or 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.

  • Page 12: System Status Light

    3.3.8 OPERATING INSTRUCTION - Figure 3.3.1H Read this information carefully before operating the vehicle. Promptly replace if removed or damaged. Contact Columbia ParCar for replacements if needed. 3.3.9 ACCELERATOR PEDAL – Figure 3.3.3I The accelerator pedal controls the speed of the vehicle in the same manner as a conventional automobile.

  • Page 13: Brake Pedal/Parking Brake

    3.3.11 WARNING LABEL - Figure 3.3.3K Read this information carefully before operating the vehicle. Promptly replace if removed or damaged. Contact Columbia ParCar for replacements if needed. 3.3.12 CHARGER RECEPTACLE & REMOTE LED The charger receptacle (Figure 3.3.2) is located on the panel near the driver’s position.

  • Page 14: Seat Switch/Traction Interlock

    3.3.15 SEAT SWITCH/TRACTION INTERLOCK – NOT SHOWN Seat switch/traction interlock requires operator in seat for traction drive operation. A reset traction controller may be required if operator leaves seats while acceleration foot pedal is depressed. 3.4 VEHICLE OPERATING INSTRUCTIONS 3.4.1 DRIVING THE VEHICLE ...

  • Page 15: Electric System

    4.0 ELECTRIC SYSTEM 4.1 IMPORTANT INFORMATION The type of battery used in a Columbia vehicle has a service requirement which is quite different from that of an automotive battery. The electric vehicle battery supplies all of the power to drive the vehicle. During operation the power stored in the batteries is expended.

  • Page 16: Battery Inspection & Maintenance

    Do not attempt to recharge batteries with a charger not designed for your vehicle. Only trained technicians should service the Delta Q charger. Contact your Columbia Dealer for assistance. 4.2 BATTERY INSPECTION & MAINTENANCE Check the electrolyte level on new batteries before they are put into service, and, at a minimum, once a week thereafter.

  • Page 17: Battery Cleaning

    If the vehicle is equipped with 12 volt batteries as shown in Figure 4.2.2, they will require watering. The cell vents are located below the covers (Figure 4.2.2 Arrows). Figure 4.2.2 Do not overfill batteries. Electrolyte expands and can overflow during charging. Water added to replace the spillage dilutes the electrolyte and reduces its specific gravity.

  • Page 18: Delta-Q Battery Charging

    4.5 DELTA-Q BATTERY CHARGING All current production Columbia 24/36/48 volt electric vehicles are built with a new solid state on-board, fully automatic Delta-Q Battery Charger (Figure 4.5A) as standard equipment. This section explains in more detail the Delta-Q Charger Operations. The Delta Q charge status can be found in two locations. On the Delta Q face and on a remote multicolored LED (Figure 4-5B).

  • Page 19: Red Light Charger Error Codes

    Charger will automatically turn on and conduct a short self-test and battery pack test. All Delta Q LED’s will flash in sequence and then a trickle current will be applied to batteries until a minimum voltage is reached. In Figure 4.5A No. 3 indicates the Bar Graph and No. 2 indicates the lowest LED. Three (3) amperes is displayed as the lowest LED on the Bar Graph.

  • Page 20: Check / Change Charging Algorithm

    4.5.3 CHECK / CHANGE CHARGING ALGORITHM he Delta-Q Charger has been programmed for use with the Columbia ParCar supplied batteries and contains ten algorithms for use with different batteries. The Table A details these battery models. TABLE A...

  • Page 21: Excessively Discharged Batteries

     Remove AC power from the charger and reconnect the charger positive connector to the battery pack. It is highly recommended to check a newly changed algorithm by repeating the above steps. 4.6 EXCESSIVELY DISCHARGED BATTERIES NOTICE: Columbia Dealer will have the equipment and experience to perform the following battery inspections. 4.6.1 DELTA-Q WILL NOT CHARGE The Delta Q will not charge dead batteries.

  • Page 22: Battery Disconnect Methods

    NOTICE: Batteries should be fully charged before performing specific gravity tests to determine battery condition. Hydrometer tests of batteries not fully charged are misleading and inconclusive. There are different type hydrometers. Carefully read and follow the instructions supplied with your hydrometer.

  • Page 23: Battery Removal & Installation

    .10 BATTERY REMOVAL AND INSTALLATION 4.10.1 24 VOLT SYSTEM  Remove battery negative (-) cables.  Remove battery positive (+) cables.  Remove battery hold down.  Remove batteries from vehicle.  To install batteries, reverse the removal procedure with the negative (-) cables being attached last. 4.10.2 48 VOLT SYSTEM The 48 volt system has the Delta-Q charger located above the batteries.

  • Page 24: Single Point Battery Watering System

    To remove batteries:  Remove battery negative (-) cables.  Remove battery positive (+) cables.  Remove battery hold down. Reverse these steps to reinstall the batteries (negative cables attached last) and to secure the charger. Be sure to retighten the two wing nuts. 4.11 SINGLE POINT BATTERY WATERING SYSTEM When equipped, this is a single point watering system for maintaining a sufficient electrolyte level in the batteries.

  • Page 25: Servicing Your Vehicle

    The parking brake is applied by depressing the parking brake pad at the top of the brake pedal which locks the brakes in place. If the brakes fail to hold the vehicle in position, contact your Columbia Dealer for qualified service assistance.

  • Page 26: Tire Care

    (Figure 5.6.2). Use a high quality wheel bearing grease. Remove the weight from the front suspension before lubricating to ensure proper grease distribution. Figure 5.6.2 Figure 5.6.1 The differential should be checked periodically for signs of leakage. Contact your Columbia Dealer for fluid replacement.

  • Page 27: Maintenance Schedule - Owner/Operator

    Check condition of tubing, couplers. Secure & Watering System leak free. Clean filter screen. 5.8 MAINTENANCE SCHEDULE - QUALIFIED TECHNICIAN Recommended that the following be performed by a trained qualified technician or your Columbia Dealer Item Operation Quarterly Semi-Annual Annual Tires Front wheel alignment and camber.

  • Page 28: Vehicle Troubleshooting

    Under inflated or flat tires. Wheels for binding, do not spin freely. If these test procedures do not resolve your vehicle problem, contact your Columbia Dealer for service. 5.10 CONTROLLER TROUBLESHOOTING The controller is located under the rear deck facing the rear of the vehicle.

  • Page 29: Towing & Transporting

    NOTICE: Never transport a vehicle behind an auto or truck unless on an approved trailer. When trailering your vehicle over long distances or on the highway observe the following:  Use trailers specifically designed to carry your Columbia ParCar vehicle that meets all federal, state and local requirements.

  • Page 30: Vehicle Storage

    7.0 VEHICLE STORAGE (over 6 weeks) 7.1 BATTERY PREPARATION Before storage make sure batteries are fully charged and the electrolyte is full in all cells per Section 4.2. Clean the batteries and connections per Section 4.3. The Delta-Q charger has the capability to test and recharge batteries during storage. Leave the batteries connected and the Delta-Q charger plugged into a reliable AC source.

  • Page 31: Returning Vehicle To Service

    7.3 RETURNING VEHICLE TO SERVICE  If necessary, connect the battery pack and fully recharge batteries.  Check tire pressure and readjust if necessary.  Complete the pre-operation checks per Section 3.4.2. For vehicles with a single point watering system: ...
  • Page 32 1115 Commercial Avenue • Reedsburg, WI 53959 Phone: (608) 524-8888 • Fax: (608) 524-8380 (800) 222-4653 • Web: www.parcar.com...

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