Columbia EX-21 EXPEDITER, IS12 Stockchaser, IR23 ROVR Owner's And Operator's Manual

Owner

and
Operator
Manual

EX-21 EXPEDITER

Electric Vehicles

P/N 709447-04

Preface

i

Welcome, and congratulations on your choice of vehicle from Columbia ParCar Corp.! Your
vehicle has been designed and manufactured to conform to applicable sections of 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. Columbia ParCar Corp. 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.

These vehicles 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.

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] • Fax: [phone]

[phone] • Web: www.parcar.com

TABLE OF CONTENTS

ii

1.0 INTRODUCTION

1.1 SAFETY MESSAGES

1.2 VEHICLE DESCRIPTION

1.3 VEHICLE IDENTIFICATION NUMBER (VIN)

1.4 VIN MATRIX

1.5 VEHICLE SPECIFICATIONS

2.0 SAFETY

2.1 GETTING STARTED

2.2 SAFETY VEHICLE STATEMENTS

2.3 SAFETY WARNINGS

2.4 SAFETY CONCERNS

3.0 OPERATIONS AND CONTROLS

3.1 IMPORTANT FIRST STEP

3.2 INSPECTING THE VEHICLE

3.3 VEHICLE CONTROLS

3.3.4 HORN BUTTON

3.3.1 POWER KEYSWITCH

3.3.2 DIRECTION SELECTOR

3.3.3 SYSTEM STATUS LIGHT

3.3.4 HORN BUTTON

3.3.5 LIGHT SWITCH

3.3.6 BATTERY STATE OF CHARGE METER

3.3.7 HOUR METER INDICATOR

3.3.8 OPERATING INSTRUCTIONS

3.3.9 ACCELERATOR PEDAL

3.3.10 BRAKE PEDAL/PARKING BRAKE

3.3.11 WARNING LABEL

3.3.12 CHARGER RECEPTACLE

3.3.13 BACKREST/REAR PASSENGER SEAT

3.3.14 STEERING WHEEL/HANDLE/TILLER

3.3.15 SEAT SWITCH/TRACTION INTERLOCK

3.4 VEHICLE OPERATING INSTRUCTIONS

3.4.1 DRIVING THE VEHICLE

3.4.2 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 DELTA-Q BATTERY CHARGING

4.5.1 CHARGER OPERATING INSTRUCTIONS

4.5.2 RED LIGHT CHARGER ERROR CODES

4.5.3 CHECK / CHANGE CHARGING ALGORITHM

4.6 EXCESSIVELY DISCHARGED BATTERIES

4.7 SPECIFIC GRAVITY TEST

4.8 TIPS FOR MAINTAINING YOUR BATTERIES

4.9 BATTERY DISCONNECT METHODS

4.10 BATTERY REMOVAL & INSTALLATION

4.10.1 24 VOLT SYSTEM

4.10.2 48 VOLT SYSTEM

4.11 SINGLE POINT BATTERY WATERING SYSTEM

5.0 SERVICING YOUR VEHICLE

5.1 MAINTENANCE GUIDELINES

5.2 MECHANICAL BRAKE SYSTEM

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

6/2008

Issued

TS

5/2011

Added above block

TS

7/12

Added remote Delta Q LED

TS

11/4/13

Corrected algorithm table

TS

iii

5.3 TIRE CARE

5.4 WHEEL & TIRE REMOVAL/INSTALLATION

5.5 CLEANING

5.6 LUBRICATION

5.7 MAINTENANCE SCHEDULE - OWNER/OPERATOR

5.8 MAINTENANCE SCHEDULE - QUALIFIED TECHNICIAN

5.9 VEHICLE TROUBLESHOOTING

5.10 CONTROLLER TROUBLESHOOTING

6.0 TOWING & TRANSPORTING

6.1 TOWING

6.2 TRANSPORTING YOUR VEHICLE

7.0 VEHICLE STORAGE

7.1 BATTERY PREPARATION

7.2 VEHICLE PREPARATION

7.3 RETURNING VEHICLE TO SERVICE

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.

Do not remove any nameplate, warnings, or instructions affixed to your Columbia Industrial
Vehicle. Promptly replace any that become damaged or removed.

1-1

1.0 INTRODUCTION

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

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 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 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. It is not approved for use on public highways.

It is designed to conform to requirements for Type E vehicles as described in O.S.H.A. Standard Section

1910.178 (Powered Industrial Trucks) and with all applicable portions of the American National Standard
for Personnel and Burden Carriers (ANSI B56.8 2006 Part III).

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 thirteen (13) digits.

The VIN number can be found in two locations. Under the rear deck, stamped in the right front corner of
the rear body chassis as shown in Figure 1.3.1. It is also on the vehicle nameplate located on the vertical
panel below the seat as shown in Figure 1.3.2.

The nameplate has important information such as model, vehicle weights and rated capacity (load,

Digit 1 thru 3 =
Abbreviation (Model)

ET2 (Three Wheel)
EF2 (Four Wheel)

Digit 7= Controller
Amperage

3 = 300 Amp
4 = 400 Amp

Digit 4 = Power
System

E = Sep Ex, Regen:
(ACEplus)

Digit 8 = Axle/Brake
System

Z = Rear Mechanical

Digit 5 = System
Voltage

2 = 24V (4 – 6 V)
B = 48V (4 – 12V)

Digit 9 = Build Year

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

Digit 6 = VIN Spacer

# = Special Product

Digit 10 Thru 13 –
Build Sequence

1234

EX21 T 24

EX21 F 24

EX21 T 48

EX21 F 48

Passenger Capacity

One or Two

Max. Speed (mph)

8

Turning
Curb to Curb (in)

127

175

127

175

Turning Intersecting Aisle (in)

66

83

66

83

Ground Clearance (in)

4

Wheelbase (in)

52.5

53.5

52.5

53.5

Overall Length (in)

84

Overall Width (in)

28.5

Overall Height (in)

46.5

Bed Size L x W (in)

21.5 x 26.0

Bed Height (in)

20.5

Tires

4.8x8, LRB (Recommend 50 psi.)

4.8x8 Foam Filled

4.0x8 Solid Non-marking

4.8x8, Non-marking (Recommend 50 psi.)

Figure 1.3.1

Figure 1.3.2

1-2

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.

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

1.4 13 DIGIT VIN MATRIX

1.5 VEHICLE SPECIFICATIONS

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 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. See Section 2.3 OPERATOR SAFETY INSTRUCTIONS.

Moving parts hazard! When operating any vehicle in a stationary position, avoid components
which could snag clothing or cause sever injury to body parts. A running vehicle must be
worked on with the greatest care.

Failure to maintain vehicle properly could result in decreased vehicle performance, reliability or
cause severe personal injury.

Always wear safety glasses or approved eye protection while performing vehicle maintenance.
This vehicle is not Federal or State DOT approved and is not equipped to be operated on public

roads or highways.
Do not exceed the rated vehicle speed. Exceeding this speed may result in steering difficulty,

motor damage, and/or loss of control and injury.
If any problems are found during scheduled maintenance or inspections, Do not operate vehicle

until repairs are made.
Failure to make necessary repairs could result in fire, property damage, severe personal injury,

or death.

2-1

2.0 SAFETY

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

2.2 SAFETY VEHICLE STATEMENTS

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

Do not overload the vehicle. Never exceed the rated capacity as specified on the Vehicle
Nameplate.

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.
 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.

 Allow only one occupant per seat. 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 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.
 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 of ramps and

platforms.

 Immediately report any accident or vehicle problem to your supervisor.

2-2

Your safety and the safety of others depend on your safe operation and maintenance of this vehicle.

2.3 OPERATOR SAFETY INSTRUCTIONS

2.4 SAFETY CONCERNS

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.

2-3

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.
 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 and should not be driven and utilized.
 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.

 Define who should and who should not drive the vehicles.
 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, semi-annually and annual vehicle inspections.

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

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 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.

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 Delta-Q Charger to charge the batteries as

described in Section 4.5.1.

 Charging is complete when the Delta-Q green 100% charge LED lights.
 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. See Section 1.5. 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 and brake light works and that the
warning buzzer sounds in reverse.