Columbia Summit, Summit Utility Owner's And Operator's Manual
Owner
and
Operator
Manual
Summit (SMT)
Summit Utility
(SUV)
Electric Vehicles
P/N 712176-02
2012 Summit
Preface
Welcome, and congratulations on your choice of a 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.
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 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
4.2
1.0 INTRODUCTION
1.1 SAFETY MESSAGES
VEHICLE IDENTIFICATION NUMBER
1.2
1.3 13 DIGIT VIN MATRIX
17 DIGIT VIN MATRIX
1.4
1.5 VEHICLE SPECIFICATIONS
2.0
2.1 GETTING STARTED
2.2
2.3
SAFETY
SAFETY GUIDELINES
SAFETY VEHICLE STATEMENTS
3.0 OPERATIONS AND CONTROLS
3.1 IMPORTANT FIRST STEP
3.2
INSPECTING THE VEHICLE
3.3
VEHICLE CONTROLS
3.3.1
3.3.2 DIRECTION SELECTOR
3.3.3 HIGH/LOW SPEED SWITCH
3.3.4 LIGHT SWITCH
3.3.5
3.3.6 BATTERY STATE OF CHARGE METER
3.3.7 SYSTEM STATUS LIGHT
3.3.8
3.3.9
3.3.10
3.3.11
3.3.12
3.3.13 TURN SIGNAL/HAZARD WARNING
S
3.3.14 HAND PARKING BRAKE
3.3.15
3.3.16 STEERING WHEEL
3.3.17 HOUR METER INDICATOR
3.3.18 HEATER
3.3.19 WINDSHIELD WASHER RESERVOIR
3.4 PRE-OPERATION CHECKLIST
DRIVING THE VEHICLE
3.5
POWER KEYSWITCH
WINDSHIELD WIPER
OPERATING INSTRUCTIONS
WARNING LABEL
ACCELERATOR PEDAL
BRAKE PEDAL
HORN BUTTON
WITCH
CHARGER RECEPTACLE
4.0 ELECTRIC SYSTEM
4.1 IMPORTANT INFORMATION
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
EXCESSIVELY DISCHARGED BATTERIES
4.6
4.7
4.8 TIPS FOR MAINTAINING YOUR BATTERIES
4.9
4.10 BATTERY PACK DISCONNECT METHODS
4.11
SYST
SPECIFIC GRAVITY TEST
BATTERY REMOVAL AND INSTALLATION
SINGLE POINT BATTERY WATERING
EM
5.0 SERVICING YOUR VEHICLE
5.1 MAINTENANCE GUIDELINES
HYDRAULIC BRAKE SYSTEM
5.2
BRAKE FLUID MAINTENANCE
5.3
5.4
TIRE CARE
WHEEL & TIRE REMOVAL/INSTALLATION
5.5
5.6
5.7
5.8
-
5.9
T
5.10
5.11
CLEANING
LUBRICATION
MAINTENANCE SCHEDULE
OWNER/OPERATOR
MAINTENANCE SCHEDULE - QUALIFIED
ECHNICIAN
VEHICLE TROUBLESHOOTING
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
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
8/2008 Issued TS
5/2011 Added above notice TS
8/12 Added remote LED and AC Drive up-date. TS
2012 Summit
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1.0 INTRO
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 maintenanc e information only. Information covering repairs is
provided in detailed service manuals availabl e from Columbia Dealers. Such major repairs req uire the attention of a
skilled technician and the use of special tools and equipment. Your Columbi a Dealer has the facilities, experience
and genuine Columbia parts and accessories to properly service Columbia vehicles.
DUCTION
1.1 SAFETY MESSAGES
Safety messages and other information in this manual are p receded by the words DANGER, W ARNING, 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. The y will pro vide key information to prevent
property damage and to assure procedures are more easily understood or implemented.
1.2 VEHICLE IDENTIFICATION NUMBER
Each vehicle contains a unique Vehicle Identification Number (VIN) which describes facts and features of the vehicle.
Summit vehicle can be configured for on road use or off road use. Vehicle with a 13 digit VIN are off road use,
Vehicles with a 17 digit VIN are on road use as N eighborhood 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.
Vehicle with a 13 digit VIN (non-NEV) will have the VIN labels in t wo locations. U
nder the steering wheel cover
and on the nameplate located in the driver’s side glove box (Figure 1-2A).
Vehicle with a 17 digit VIN (NEV) will have the VIN labels in three locatio ns. Under the steering wheel cover, on
the nameplate located in the driver’s side glove box (Figure 1-2A) and on the top of the dash (Figure 12B).
NEV vehicle will also have an Operating Restrictions label (Fig
restrictions for neighborhood electric vehicles. Do not remove this label.
The nameplate contains important vehicle information such as vehicle weights and maximum load. Read carefully.
ure 1-2C). This label provides important operation
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A
Digit 1 – 3 Model
Digit 4 Power Systems
B
C
A
Figure 1-2
1.3 13 DIGIT VIN MATRIX
S2T = 2-Passenger
S4T = 4 Passenger
SUS = Short Bed Utility
SUL = Long Bed Utility
E = DC Drive Sep Ex, Regen
F = DC Drive Sep Ex, Regen w/ encoder
G = AC Drive Induction Motor
Digit 5 Voltage/Batteries
Digit 6 Standard or Special Product
Digit 7 Controller Amperage
Digit 8 Axle/Brake System
Digit 9 Year Built
Digits 10 – 13 Build Sequence
4 = 48 Volt (8 – 6 Volt)
G = 48 Volt Gel (8 – 6 Volt)
- = Standard Product
# = Special Product
3 = 300 Amp DC
4 = 400 Amp DC
5 = 500 Amp DC
Z = H12: Rear Mechanical
Y = H12: Rear Hydraulic
X = H12: Front & Rear Hydraulic
L = 2012, M = 2013, N = 2014, etc.
0000 Through 9999
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Digit 1 – 3 Mfg. ID
Digit 4 Vehicle Type
Digit 5 Series
Digit 6 Body Type
Digit 7 Engine Type
1.4 17 DIGIT VIN MATRIX
5FC = Columbia ParCar
L = Low Speed Vehicle
S = Summit
2 = Two Person
3 = Long Bed
4 = Four person
5 = Short Bed
6 = 48 Volt DC Drive
8 = 48 Volt AC Induction Drive
Digit 8 Restraint
Digit 9
Digit 10 Model Year
Digit 11 Plant Location
Digit 12 - 17
A = Type 1 Seat Belt Assembly
B = Type 2 Seat Belt Assembly (3 point)
Assigned Check Digit
B = 2011, C = 2012, D = 2013 etc.
1 = Reedsburg
123456 = Build Sequence
To ensure prompt service when repairs or adjustments are required, your Columbia Dealer must have the VIN.
An example of a current 13 digit VIN is SUSEB-4YL1234
An example of a current 17 digit VIN is 5FCLS36A681123456.
For your own personal reference, fill in the VIN in the space provided below:
1.5 VEHICLE SPECIFICATIONS
Max. Speed
Max. Range* Up to 40 miles Up to 35 miles Up to 40 miles Up to 35 miles
Passenger 2 4 2 2
Power 48 Volt DC Drive Standard, 48 Volt AC Drive Optional
Brakes Hydraulic rear drums, Hand parking brake
Overall
L x W x H (Inches)
Wheelbase 66 92 76 91
Ground Clearance (Inches) 5.5
Flat Bed (inches) - - 36 x44 60 x 44
Curb Weight (lbs) 1500 1780 1600 1750
Gross Vehicle Weight (lbs) 2090 2550 2338 2735
Lighting – Non-NEV do not
have all listed
Windshield/Mirrors Safety Glass Windshield, Rear & Side Mirrors
Charger Built-in, micro-processor controlled with remote LED
Battery Eight, 6 volt
SM-2 SM4 SUV-S SUV-L
19 mph non-NEV
25 mph NEV
99 x 48 x 72 124 x 48 x 72 107 x 48 x 72 131 x 48 x 72
Headlights, Taillights, Brake Lights, Back-up Lights,
Emergency Flashers, Reflectors, License Plate, Turn Signals
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2.0 SAFETY
2.1 GETTING STARTED
For personal safety before operating the vehicle, it is the operator’s responsibility to rea d, 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 p erson 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 fo llowing warnings must be observed at all
times. Not all are repeated throughout this manual, but the recomm endations 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 responsibilit y. Whi le
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
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 lo cation.
Failure to maintain the vehicle properly or any modifications or changes that affect the stability, steering
or that results in increased speed beyond factory specification s could result in vehicle damage, severe
personal injury or death.
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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.
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 maximum load 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.
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.
Use only genuine Columbia vehicle replacement parts.
No modifications or additions, which affect the mechan ical o r electrical in tegrity an d th e saf e ope ration o f
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.
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3.0 OPERA
TIONS AND CONTROLS
3.1 IMPORTANT FIRST STEP
Upon initial delivery, it is very important that the battery pack is pr operly charged. This is required if th e 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 ins pect each cell for proper electrolyte level. If the electrolyte level is bel ow
the plates add only enough water to cover the plates. See Section 4.2.
For sealed batteries, do NOT attempt to remove caps or open vents. See Section 4.2.
NOTICE: Do not overfill a cell. Electrolyte expands and can overflow during charging.
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 4.2.2.
Vehicles with a single point watering system will require completion of 4 to 5 charge cycles before watering.
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.
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.
NOTICE: Vehicle should be inspected immediately after delivery. Use the following guidelines to make
sure there are no obvious problems.
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.
nspect the tires for obvious wear or damage. Check for proper tire inflation. Refer to manufactures recommendatio n
I
imprinted on tire sidewall. 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.
NOTICE: Each control should operate smoothly and easily without sticking or requiring excessive effort.
Horn, check for proper operation.
Check that the warning buzzer sounds in reverse.
Head lights, brake and tail lights, emergency flasher operating.
Directional selector switch, check for proper operation.
If vehicle has just been delivered, report any ph ysical damage or missing items to the shipping company and your
local Columbia Dealer.
Report any battery or service issue problems to the i ndividual(s) responsible for correction and/or repair or contact
your local Columbia Dealer for service.
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