Columbia EAGLE P4 Owner's And Operator's Manual

Owner

and

Operator

Manual

EAGLE P4 Electric Vehicles

P/N 712081-05 2015

Preface

i

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] • [phone] • Web: www.parcar.com

P4 Owner’s Manual 2015

TABLE OF CONTENTS

ii

1.0 INTRODUCTION

1.1 SAFETY MESSAGES

1.2 VEHICLE IDENTIFICATION NUMBER

1.3 VIN MATRIX

1.4 VEHICLE SPECIFICATIONS

2.0 SAFETY

2.1 GETTING STARTED

2.2 SAFETY GUIDELINES

2.3 SAFETY VEHICLE STATEMENTS

2.4 BATTERY DISCONNECT METHODS

3.0 OPERATIONS AND CONTROLS

3.1 IMPORTANT FIRST STEP

3.2 INSPECTING THE VEHICLE

3.3 VEHICLE CONTROLS

3.3.1 POWER KEYSWITCH

3.3.2 DIRECTION SELECTOR

3.3.3 LIGHT SWITCH

3.3.4 AUXILIARY EQUIPMENT SWITCH

3.3.5 BATTERY STATE OF CHARGE METER

3.3.6 WARNING LABEL & OPERATING INSTRUCTIONS

3.3.7 SYSTEM STATUS LIGHT

3.3.8 BRAKE PEDAL/PARKING BRAKE

3.3.9 ACCELERATOR PEDAL

3.3.10 HOUR METER INDICATOR

3.3.11 STEERING WHEEL

3.3.12 CHARGER RECEPTACLE

3.3.13 TURN SIGNAL/HAZARD WARNING SWITCH

3.3.14 HORN BUTTON

3.3.15 CAB HEATER

3.4 MAINTENANCE ACCESS

3.5 DRIVING THE VEHICLE

3.6 PRE-OPERATION CHECKLIST

4.0 ELECTRIC SYSTEM

4.1 IMPORTANT INFORMATION

4.2 BATTERY INSPECTION & MAINTENANCE

4.3 BATTERY CLEANING

4.4 CONDITIONS WHICH AFFECT CHARGING

4.5 BATTERY CHARGERS

4.6 DELTA Q CHARGING SYSTEM

4.6.1 CHARGER OPERATING INSTRUCTIONS

4.6.2 RED LIGHT CHARGER ERROR CODES

4.6.3 CHECK / CHANGE CHARGING ALGORITHM

4.7 PRO CHARGING SYSTEM

4.7.1 TROUBLE SHOOTING

4.7.2 LIGHT EMITTING DIODES (LED) FAULT CODE INDICATIONS

4.8 EXCESSIVELY DISCHARGED BATTERIES

4.9 SPECIFIC GRAVITY TEST

4.10 TIPS FOR MAINTAINING YOUR BATTERIES

4.11 BATTERY REMOVAL & INSTALLATION

4.12 SINGLE POINT BATTERY WATERING SYSTEM

P4 Owner’s Manual 2015

5.0 SERVICING YOUR VEHICLE

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

5/2011

Added above block

TS

7/11/12

Added Delta Q remote LED

TS

11/11/13

Corrected algorithm table

TS

5/11/15

Corrections and added PRO Charger, added LSV

TS

iii

5.1 MAINTENANCE GUIDELINES

5.2 MECHANICAL BRAKE SYSTEM

5.3 HYDRAULIC BRAKE SYSTEM

5.4 BRAKE FLUID MAINTENANCE

5.5 TIRE CARE

5.6 WHEEL & TIRE REMOVAL/INSTALLATION

5.7 CLEANING

5.8 LUBRICATION

5.9 MAINTENANCE SCHEDULE - OWNER/OPERATOR

5.10 MAINTENANCE SCHEDULE - QUALIFIED TECHNICIAN

5.11 VEHICLE TROUBLESHOOTING

5.12 CONTROLLER TROUBLESHOOTING

6.0 TOWING & TRANSPORTING

6.1 TOWING YOUR VEHICLE

6.2 TRANSPORTING YOUR VEHICLE

7.0 VEHICLE STORAGE

7.1 BATTERY PREPARATION

7.2 VEHICLE PREPARATION

7.3 RETURNING VEHICLE TO SERVICE

P4 Owner’s Manual 2015

1.0 INTRODUCTION

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.

Figure 1.2.2

Figure 1.2.1

1-1

This manual provides important safety information, operating instructions, model specifications and
maintenance instructions for Eagle electric vehicles.

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.

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.

1.2 VEHICLE IDENTIFICATION NUMBER

Each vehicle contains a unique Vehicle Identification Number (VIN). The VIN describes facts and features
of the vehicle and contains thirteen (13) digits. The VIN labels can be found in several locations.

Under the steering wheel cover as shown in Figure 1.2.1. Access to this location is by removing the three
screws holding the cover in place.

The other location will be in the driver side glove box as shown in Figure 1.2.2.

To ensure prompt service when repairs or adjustments are required, your Columbia Dealer must have the
VIN.

An example of a current VIN is P4LF4-3YF1234.

P4 Owner’s Manual 2015

Digit 1 – 3
Model

P4L = Eagle - LE

P4S = Eagle - SE

Digit 4
Power Systems

C = Sep. Ex, Plug: (Smartdrive)

E = Sep Ex, Regen: (ACEplus)

F = Sep Ex, Regen w/ encoder: (ACEplus)

Digit 5
Voltage/Batteries

3 = 36 Volt

4 = 48 Volt (8 – 6 Volt)

B = 48 Volt (4 – 12 Volt)

G = 48 Volt Gel (8 – 6 Volt)

Digit 6
Standard or Special Product

- = Standard Product

# = Special Product

Digit 7
Controller Amperage

3 = 300 Amp

4 = 400 Amp

5 = 500 Amp

Digit 8
Axle/Brake System

Z = H12: Rear Mechanical

Y = H12: Rear Hydraulic

X = H12: Front & Rear Hydraulic

Digit 9
Year Built

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

Digits 10 – 13
Build Sequence

0000 Through 9999

1-2

For your own personal reference, fill in the VIN in the space provided below:

1.3 VIN MATRIX

13 DIGIT VIN – USED AFTER FEBRUARY 2006

P4 Owner’s Manual 2015

1.4 VEHICLE SPECIFICATIONS

MODELS

LE-48

SE-48

Speed

19 mph

Passenger Capacity

2

Turning
Curb to Curb

255 in.

Ground Clearance

5 in.

Wheelbase

64.5 in.

Overall Length

96 in.

Overall Width

45 in.

Overall Height

51 in.

Horsepower

15.3 HP @ 1750 rpm

17.3 HP @ 1750 rpm

Brakes

Auto adjusting, dual mechanical rear drum,

parking brake automatically releases

TIRES

RECOMMENDED PSI

215/60-8

18.5 x 8.5 – 8 non-marking
205/50-10
480-12
165/65R13
215/50R13
175/70R13

22 – 25 psi
22 – 25 psi
30 psi
32 psi
32 psi
32 psi
32 psi

DRIVE RATIO

LE

12.44:1

SE

10.35:1

1-3

P4 Owner’s Manual 2015

2.0 SAFETY

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 Corp.
Customer Service.

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.

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

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.

2.2 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.

2.3 SAFETY VEHICLE STATEMENTS

P4 Owner’s Manual 2015

 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 keyswitch is in position for the desired direction of travel before

depressing the accelerator. Do not change the directional keyswitch 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.
 This vehicle is not Federal or State DOT approved and is 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.
These basic rules of operation, combined with courtesy and common sense, will help make

driving your Columbia vehicle a safe and pleasant experience.

2-3

2-2

2.4 BATTERY DISCONNECT METHOD

The following illustrates the battery configuration. Disconnect both battery leads (Main Solenoid and
Controller B-) before performing any vehicle service.

P4 Owner’s Manual 2015

3.0 OPERATIONS AND CONTROLS

NOTICE: Do not overfill a cell. Electrolyte expands and can overflow during charging.

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.

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.

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.

 Check that the batteries are not damaged or leaking and that connections are tight.
 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. See Section 4.2.

 For vehicles with a single point watering system, replace the manifold assemblies with a ¼ clockwise

turn.

 With the electrolyte level correct, use the on board charger to charge the batteries as described in

Section 4.

 Charging is complete when the green LED 100% charge is lit.
 Vehicles without a single point watering system, refill cells to below the bottom of the each cell vents.

See Figure 4.2.1.

 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 recommendations in

Section 1.4. 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.

P4 Owner’s Manual 2015

Report any battery or service issue problems to the individual(s) responsible for correction and/or repair

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.

NOTICE: Direction selector must be in the N or neutral position prior to turning on the ACEplus
or Smartdrive power keyswitch, or a reset of the direction selector to neutral will be required
before traction drive is enabled. See Section 5.12 CONTROLLER TROUBLESHOOTING.

Figure 3.3.1

3-2

A B C

D E G

H I J

K

F

or contact your local Columbia Dealer for service.

3.3 VEHICLE CONTROLS

This section describes the operating controls of the vehicle. Figure 3.3.1 identifies many of these controls.

3.3.1 POWER KEYSWITCH – Figure 3.3.1 –Arrow A

With the power keyswitch in “OFF” position, the Traction System is powered down. This conserves

battery energy by reducing the power draw when vehicle is not in use. Turning the power keyswitch to
OFF is highly recommended whenever vehicle is not in use. Always take the key out of the keyswitch
when leaving the vehicle.

3.3.2 DIRECTION SELECTOR – Figure 3.3.1 - Arrow B

When the direction selector is in the vertical position, the vehicle’s direction signal is turned OFF or in
neutral.

Turn direction selector to the right from vertical position to move the vehicle in forward direction. Turn
direction selector to the left from vertical position to move the vehicle in reverse direction. A warning
buzzer sounds when in reverse.

P4 Owner’s Manual 2015