Columbia Expediter EX-21 2017, Stockchaser IS12 2017, Utilitruck EU4-S 2017, Utilitruck EU4-L 2017 Owner's And Operator's Manual

2017

Model
EX-21

Expediter

PN 709447-05
7/2016

Owner and Operator Manual

Preface

CHANGE HISTORY

DATE

DESCRIPTION

BY

7/1/2016

Issued 2017 Model Year

CPC

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.

Thes

e 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.

the best knowledge of Columbia ParCar Corp., the material contained herein is accurate as

To
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.

This manual provides important safety information, operating instructions, model specifications
and maintenance instructions for the EX 21 Expediter.

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.

1115 Commercial Avenue • Reedsburg, WI 53959

Phone: [phone] • Fax: [phone]

[phone] • Web: www.columbiausa.com

Expediter EX-21

2017

TABLE OF CONTENTS

INTRODUCTION PAGE

TABLE OF CONTENTS .................................................................................................. 1

SAFETY MESSAGES ..................................................................................................... 2

VEHICLE DESCRIPTION ................................................................................................ 3

VEHICLE IDENTIFICATION NUMBER LOCATION ........................................................ 3

VEHICLE IDENTIFICATIO N NUMBER DECODING........................................................ 4

VEHICLE SPECIFICATIONS .......................................................................................... 4

SA

FETY

GETTING STARTED ....................................................................................................... 5

SAFETY GUIDELINES .................................................................................................... 5

VEHICLE SAFETY STATEMENTS ................................................................................. 5

ADDITIONAL OPERATING SAFET Y CONCERNS ......................................................... 7

OPE

RATIONS AND CONTROLS

IMPORTANT FIRST STEP .............................................................................................. 7

INSPECTING THE VEHICLE .......................................................................................... 8

WHAT TO DO IN EVENT OF A PROBLEM NOTICED DURING INSPECTION .............. 8

VEHICLE CONTROLS .................................................................................................... 9

KEY SWITCH .................................................................................................................. 9

DIRECTION SELECTOR KNOB ..................................................................................... 9

SYSTEM STATUS LIGHT ............................................................................................... 9

LIGHT SWITCH ............................................................................................................... 9

BATTERY STATE OF CHARGE ..................................................................................... 9

HORN SWITCH ............................................................................................................... 9

OPERATING INSTRUCTIO N LABEL .............................................................................. 9

ACCELERATOR PEDAL ................................................................................................. 10

BRAKE PEDAL ............................................................................................................... 10

OPERATOR WARNING LABEL ...................................................................................... 10

ADDITIONAL IN FORMATION LABEL ............................................................................. 10

PRE-OPERATION CHECKLIST ...................................................................................... 11

DRIVING THE VEHICLE ................................................................................................. 12

BACKREST POSITION ................................................................................................... 12

STEERING THE VEHICLE .............................................................................................. 12

ELECTRIC SYSTEM

BATTERY INSPECTION & MAINTENANCE ................................................................... 14

BATTERY CLEANING ..................................................................................................... 15

CONDITIONS WHICH AFFECT CHARGING .................................................................. 16

BATTERY CHARGING SYSTEM .................................................................

CHARGER ERROR CODES ........................................................................................... 18

CHARGER INTERNAL ALGORITHM SETT ING .............................................................. 19

EXCESSIVELY DISCHARGED BATTERIES .................................................................. 20

BATTERY REMOVAL & INSTALLATION ........................................................................ 20

TIPS FOR PROLONGING BATTERY LIFE ..................................................................... 21

SINGLE POINT WATERING SYSTEM ............................................................................ 21

................... 17

Expediter EX-21

Page 1

SERVICING YOUR VEHICLE

hazardous situation which, if not avoided, will result in death or

serious injury.

serious injury.

moderate injury.

MAINTENANCE SCHEDULE - OWNER/OPERATOR..................................................... 22

MAINTENANCE SCHEDULE - QUALIFIED TECHNICIAN .............................................. 23

MAINTENANCE GUIDELINES ........................................................................................ 23

LIFTING INS TR U CTIONS ............................................................................................... 23

BRAKE PEDAL ............................................................................................................... 24

TIRE CARE/WHEEL REMOVAL ..................................................................................... 24

CLEANING ...................................................................................................................... 25

LUBRICATION ................................................................................................................ 25

VEHICLE TROUBLESHOOTING .................................................................................... 25

CONTROLLER TROUBLESHOOTING ........................................................................... 26

VEHI

CLE STORAGE

BATTERY PREPARATION ............................................................................................. 27

VEHICLE PREPARATION .............................................................................................. 28

RETURNING VEHICLE TO SERVICE ............................................................................ 28

TOWING AND TRANSPORTING .................................................................................... 28

WAR

RANTY

WARRANTY INFORMATION .......................................................................................... 29

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

Warning indicates a hazardous situation which, if not avoided, could result in death or

Caution indicates a hazardous situation which, if not avoided, could result in minor or

NOT

ICE: 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.

Expediter EX-21

Page 2

VEHICLE DESCRIPTION

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 is recorded on the vehicle
nameplate which is located on the left

The VIN is also stamped on the metal

The nameplate also has other important
information such as vehicle weights and

Do not exceed this capacity.

This rated capacity includes cargo and

adjustments are required, your Columbia

NOTICE: Always provide the complete VIN when contacting your dealer for technical
assistance or maintenance and repair parts.

Expediter is a single operator vehicle involving sit-down operation, with capacity for one

The
rear facing passenger. This vehicle is designed to be driven on smooth surfaces in and around
industrial plants, warehousing, institutions, motels, mobile home parks, and resorts.

s vehicle is not designed to be driven on public highways. It is designed to conform to

Thi
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 1993 Part III).

VEHICLE IDENTIFICATION NUMBER (VIN)

The VIN can be found in two locations.

side of the operator’s position.

cross bar located under the rear deck
platform.

capacity.
operator.
To ensure prompt service when repairs or
Dealer must have the VIN.

For y

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

____________________________________________

Expediter EX-21

Page 3

Digit 1 thru 3 = Abbreviation (Model)

ET2 = 3 Wheel, ET4 = 4 Wheel (EX21 - Expediter)

Digit 4 = Power System

E = Separately Excited Regenerative

Digit 5 = System Voltage

2 = 24V, 4 = 48V

Digit 6 = VIN Spacer

- = normal

# = Special Product

Digit 7= Controller Amperage

3 = 300A, 4 = 400A

Digit 8 = Axle/Brake System

Z = Rear Mechanical

Q = 2016, R = 2017, S = 2018 etc.

(Letters I & O not used)*

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)

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

4.8x8, LRB (Recommend 50 psi.)

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

Digit 9 = Build Year

VIN MATRIX - 13 DIGIT VIN

VEHICLE SPECIFICATIONS

127 175 127 175

Tires

4.8x8 Foam Filled

4.0x8 Solid Non-marking

Expediter EX-21

Page 4

GETTING STARTED

severe personnel injury or death.

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.

Please be a safe operator. Electric vehicles are only as safe as the person who is at the
controls. If accidents are to be prevented, operators must accept their full measure of
responsibility. While the designer, the manufacturer, the dealer 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-operating rules.

VEHICLE SAFETY 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 result
in increased speed beyond factory specifications could result in vehicle damage,

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.

Expediter EX-21

Page 5

Only trained service professionals should repair or service this vehicle. Persons doing

even simple repairs or maintenance should have working knowledge and experience in

Failure to maintain vehicle properly could result in decreased vehicle performance,

Always wear safety glasses or approved eye protection while performing vehicle

Drive slowly in turns and up and down grades. Do not make turns on steep hills or

To avoid the risk of injury or vehicle damage, operate at maximum speed only on

general electrical and mechanical repair.
Foll

ow 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.

ing parts hazard! When operating any vehicle in a stationary position, avoid

Mov
components which could snag clothing or cause severe injury to body parts. A running
vehicle must be worked on with the greatest care.

reliability or cause severe personal injury.

maintenance.
Thi

s 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.

er exceed the capacity ratings of the vehicle. Exceeding these limits may endanger

Nev
occupant or cause vehicle damage.

Com

pletely stop vehicle before stepping off.

If

vehicle is to be left unattended, turn keyswitch to “OFF” and remove key.

inclines.
Do not

operate while under the influence of alcohol or drugs.

smooth flat surfaces.
Al

low additional stopping distance when traveling at higher speeds.

not drive this vehicle in hazardous areas unless this vehicle is approved and

Do
labeled for such operation.

Expediter EX-21

Page 6

ADDITIONAL OPERATION SAFETY CONCERNS

NOTICE: The following information does NOT apply to sealed batteries.

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

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.

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.

ery owner or renter of this vehicle must, at a minimum:

Ev

 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.

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.

 With the electrolyte level correct, use the on board charger to charge the batteries.

Charging is complete when the remote LED is steady green.

 Vehicles without a single point watering system, after charging, refill cells to below the

bottom of each cell vent.

Expediter EX-21

Page 7

INSPECTING THE VEHICLE

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.

Upon r

eceipt of vehicle, 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.

amine the contents of all packages and accessories that may have come in separate

Ex
packages with this vehicle. Make sure everything listed on the packing slip is there. Items
should not be broken or damaged.

Ex

amine any visible wiring for obvious signs of damage. Check that all connections are secure.
Check that battery connections are tight and all cells are filled to above plates. Check for
damaged or leaking batteries.

Ins

pect the tires for obvious wear or damage. Check for proper tire inflation. Refer to
manufactures recommendation imprinted on tire sidewall. Make sure that all wheel lugs are
secure.

k the body and other parts f or obvious damage. Look for body damage, jagged edges etc.

Chec
that may cause personal injury.

Oper

ate each of the following controls before turning on the power keyswitch.

 Accelerator and Brake Pedals
 Steering Wheel, Handle Bar or Tiller Bar

k that the horn sounds and that the key can only be removed when keyswitch is in the

Chec
“OFF” position.

WHAT TO DO IF YOU HAVE A PROBLEM

vehicle has just been delivered, report any physical damage or missing items to t he shipping

If
company and your local Columbia Dealer.

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

Repor
contact your local Columbia Dealer for service.

Expediter EX-21

Page 8