Columbia Van, Dropside, TiltBed, Cargo, Refuse Owner's And Operator's Manual

Owner
and
Operator Manual

MEGA NEV & Utility
Electric Vehicles

Van
Dropside
TiltBed
Cargo
Refuse

712112-05

2013 MEGA

PREFACE

i

Welcome, and congratulations on your choice of the Columbia Electric Vehicle from Columbia ParCar Corp.!

Vehicle with a 13 digit VIN are off road use as Personal Transport Vehicles (PTV). Vehicles with a 17 digit VIN are on
road use as Low Speed Vehicle (LSV) also known as Neighborhood Electric Vehicles (NEV’s). These 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.

Some of the equipment in this manual may not apply to your vehicle, depending on which model you have.
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 Par-Car 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.

A member of the Nordic Group of Companies

1115 Commercial Avenue, Reedsburg, WI 53959

Phone - 608.524.8888 Fax - 608.524.8380

www.parcar.com

2013 MEGA

TABLE OF CONTENTS

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

8/08

Issued

TS

8/12

Added Delta Q remote LED and update

TS

4/13

Up-dated heater picture and maintenance section.

TS

11/12/13

Corrected algorithm table.

TS

ii

1.0 GENERAL INFORMATION

1.1 SAFETY MESSAGES

1.2 SPECIFICATIONS

1.3 VEHICLE IDENTIFICATION NUMBER
(VIN)

1.4 VIN MATRIX Utility)

1.5 VIN MATRIX (NEV)

2.0 SAFETY

2.1 GETTING STARTED

2.2 VEHICLE SAFETY

2.3 OPERATION SAFETY

2.4 CHILD SAFETY

2.5 CONCERNS

3.0 OPERATION

3.1 IMPORTANT FIRST STEP

3.2 INSPECTING THE VEHICLE

3.3 SEATS AND SEAT BELTS

3.4 FRONT DOORS

3.5 HEATER

3.6 HAZARD WARNING FLASHER

3.7 INSTRUMENT PANEL

3.8 WINDSHIELD WIPER

3.9 LIGHTS, HORN & TURN SIGNALS

3.10 INTERIOR LIGHT

3.11 12V POWER OUTLET

3.12 MULTIFUNCTIONAL DISPLAY
INDICATOR (MDI)

3.13 WINDSHIELD DEFROST SWITCH

3.14 KEYSWITCH

3.15 DIRECTIONAL KNOB

3.16 HANDBRAKE

3.17 CHARGER RECEPTACLE & REMOTE
LED

4.0 DRIVING THE VEHICLE

4.1 PRE-OPERATION CHECKLIST

4.2 STARTING AND STOPPING

4.3 BATTERIES

4.4 RECOMMENDED BREAK-IN PERIOD

4.5 TILTBED/REFUSE LOADING

4.6 TILTBED/REFUSE, RAISING AND
LOWERING

5.0 ELECTRICAL

5.1 IMPORTANT INFORMATION

5.2 FUSE BOX – 48V CIRCUIT

5.3 FUSE BOX – 12V CIRCUIT

5.4 BATTERY MAINTENANCE

5.5 BATTERY CLEANING

5.6 CONDITIONS WHICH AFFECT
CHARGING

5.7 DELTA-Q BATTERY CHARGING

5.7.1 CHARGER OPERATION

5.7.2 RED LIGHT CHARGER
ERROR CODES

5.7.3 CHECK/CHANGE CHARGING
ALGORITHM

5.8 EXCESSIVELY DISCHARGED
BATTERIES

5.9 SPECIFIC GRAVITY TEST

5.10 TIPS FOR PROLONGING BATTERY
LIFE

5.12 SINGLE POINT WATERING SYSTEM

6.0 SERVICING YOUR VEHICLE

6.1 MAINTENANCE GUIDELINES

6.2 TILT BED SAFETY

6.3 REFUSE SAFETY

6.4 CLEANING

6.5 MAINTENANCE INDICATOR

6.6 MAINTENANCE SCHEDULE –
OWNER/OPERATOR

6.7 MAINTENANCE SCHEDULE –
QUALIFIED TECHNICIAN

6.8 SPARE TIRE

6.9 TIRE PRESSURE

6.10 REPLACING BULBS

6.11 CHECKING BRAKE FLUID LEVEL

6.12 WINDSHIELD WASHER FLUID

6.13 TILT MECHANISM

6.14 TRAILERING THE VEHICLE

6.15 VEHICLE STORAGE

6.16 VEHICLE TROUBLESHOOTING

2013 MEGA

1.0 GENERAL 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.

Van

DropSide

TiltBed

Cargo

Refuse

Overall Length (in.)

129

Overall Width* (in.)

60

60.2

58.7

60.2

Overall Height (in.)

73

70.9

72.1

Wheel Base (in.)

91

Ground Clearance (in.)

7

Weight (lbs.)

1573

1562

1646

1452

1782

Rated Capacity (lbs.

1177

1188

1104

1298

650

1-1

This manual provides important safety information, operating instructions, model specifications and maintenance
instructions for the vehicle.

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 skilled technicians 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.

1.1 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.

* Excluding mirrors

1.2 SPECIFICATIONS

2013 MEGA

All Models

Passenger Capacity

2

Maximum Rated Speed

up to 25 MPH

Range-Standard Battery Group

Up to 40 miles**

Turning Radius

19 feet

Traction Power System

48 Volt

Motor

5 KW AC

Speed Control

Solid state, regenerative braking

Charger

110-240 VAC, 50/60 Hz

Drive

Front wheel, direct

Steering

Rack & Pinion

Hydraulic Brakes-Front/Rear

Disc/Drum

Independent Suspension-Front

McPherson strut/Coil

Independent Suspension-Rear

Coil/Shock

Tires

145/70R13. Recommend 29 psi.

Chassis

Aluminum construction

Do not remove any nameplate, warnings, or instructions affixed to the Columbia vehicle. Promptly replace
any that become damaged or removed.

Figure 1.3

1-2

** Range will vary depending upon load, temperature, terrain and driving style.

1.3 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 17 digits

(LSV) or 13 digits (PTV).
The VIN can be found in four locations: on the top section of the dash,

under the steering wheel cover (Figure 1.3), in the glove box and below the
drive seat.

Record the VIN here and provide this number to the dealer when repairs or
adjustments are required.

VIN

2013 MEGA

1.4 VIN MATRIX – Personal Transport Vehicle

Digit 1 thru 3: Model Group

MGA = Utility, MGC = Cargo Bed,
MGD = DropSide MGT = TiltBed,
MGV = Van Bed

Digit 4: Power System

E = Separately Excited Regen/ACE+ System
G = AC Drive Induction

Digit 5: System Voltage/Batteries

4 = 48V (8-6V)
G = 48V GEL (8-6V), M = 48V AGM (8-6V)

Digit 6: Standard or Special Product

- = Standard Product
* = Special Product

Digit 7: Controller Amperage

4 = 400 Amp 5 = 500 Amp

Digit 8: Axle Brake System

N = Front Wheel Drive: F & R Hydraulic

Digit 9: Model Year

L = 2012, M = 2013, N = 2014 etc.

Digit 10-13: Build Sequence

0000 - 9999

Digit 1 thru 3: Manufacturer Identification

5FC = CPC
Digit 4: Line

L = Low Speed Vehicle

Digit 5: Series

M = MEGA

Digit 6: Body Type

2 = 2 Person 3 = Long Bed
4 = 4 Person 5 = Short Bed

Digit 7: Engine Type

6 = Separately Excited 48V ACE+ System
8 = 48V AC Induction Drive

Digit 8: Restraint

A = Type 1 Seat Belt Assembly
B = Type 2 Seat Belt Assembly (3 Point)

Digit 9: Check Digit

Calculated per IAW 49CFR 565.4

Digit 10: Model Year

C = 2012, D = 2013. E = 2014

Digit 11: Plant Location

1 = Reedsburg

Digit 12-17: Sequential Numbers

00019 - 000999

Vehicles with a 13 digit VIN are not Federal or State DOT approved and is not equipped to be operated on
public roads or highways.

Vehicle with a 17 digit VIN are Federal or State DOT approved and are equipped to be operated on public
roads or highways.

1-3

1.5 VIN MATRIX- Low Speed Vehicle

2013 MEGA

2.0 SAFETY

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.

Only trained service professionals should repair or service this vehicle. Persons doing even simple repairs
or maintenance should have a 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.

If any problems are found during scheduled maintenance or inspections, do not operate vehicle until
repairs are made.

Always wear safety glasses or approved eye protection when performing vehicle maintenance.

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 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. If in doubt about any modification, contact your local Columbia Dealer or
Columbia ParCar Corp. Customer Service.

Do not overload the vehicle. Never exceed rated capacity as specified on the vehicle nameplate.
Failure to maintain vehicle properly or make necessary repairs could result in decreased vehicle

performance, reliability or cause severe personal injury.

2-1

2.1 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 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 (operator safety, battery hazards, etc.) are encountered. Section 4.0 ELECTRIC SYSTEM contains
important safety and other system information.

2.2 VEHICLE SAFETY

Your safety and the safety of others depend on your safe operation and maintenance of this vehicle. Prior to
operation, you, the operator, must be thoroughly familiar with this and all other sections of this manual.

2.3 OPERATION SAFETY

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.

2013 MEGA

Do not drive this vehicle unless you are a qualified and trained operator and familiar with the vehicle
operational controls.

All vehicles should be operated from the driver’s side.
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 with seat belts fastened, if equipped. 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 the key.

Do not use accelerator to hold vehicle on an incline. Use brake.
Make sure gear selector is in the desired direction of travel before depressing the accelerator. Do not

change gear selector position 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.
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.
Keep a safe distance when following other vehicles and from the edge or ramps and platforms.
Immediately report any accident or vehicle problem to your supervisor.

Never leave a child or animal in a vehicle exposed to the sun with the windows closed.
Never leave the keys with a child in the vehicle.
Child seats are not recommended for this vehicle.
It is imperative to follow your local laws where you are driving, particularly in respect to driving with

children of specific ages in the front seats of the vehicle.

2-2

2.4 CHILD SAFETY

2013 MEGA

2.5 CONCERNS

2-3

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.

At 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 be driven and utilized and should and who should not drive the vehicles.
 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.
 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,

semiannually and annual vehicle inspections.

 Determine who, when, and how pre-operation inspections be conducted.
 Notify operators what to do should an unsafe condition or operating problem be discovered.

2013 MEGA

3.0 OPERATIONS AND CONTROLS

NOTICE: If the vehicle is not going to be used the Delta-Q Charger can remain connected to an AC source.
It has the capability to test and recharge the battery pack during storage.

NOTICE: Vehicle should be inspected immediately after delivery. Use the following guidelines to make
sure there are no obvious problems.

NOTICE: Each control should operate smoothly and easily without sticking or requiring excessive effort.

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.

3-1

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.
 Charging is complete when the Delta-Q green 100% charge LED lights. There is a remote LED located next to

the charger receptacle. See Section 3.16.

 Vehicles with a single point watering system will require completion of 4 to 5 charge cycles before watering.

3.2 INSPECTING THE VEHICLE

After battery charging, 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.

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. Refer to recommendation in Section 1.2.
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.
 Steering, check for responsiveness and little play.
 Key can only be removed when keyswitch in “OFF” position.

Check that the directional selector operates properly, that the horn works and that the warning buzzer sounds in
reverse.

If vehicle has just been delivered, report any physical damage or missing items to the shipping company and your
local 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.

2013 MEGA