Columbia SU5 Manuel utilisateur

Owner and Operator Manual

SU5

P/N 712307 CPC P/N 99727-14 2014

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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: (608) 524-8888 • Fax: (608) 524-8380

(800) 222-4653 • Web: www.parcar.com

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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

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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

5/1/14

Issued

iii

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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

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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

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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

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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

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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

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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

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