Columbia Summit SU5-L-2 2017, Summit SU5-S-2 2017 Owner's And Operator's Manual

2016

Model
SU5-S/L

PN 712307-01
6/2016

Summit
Utilitruck

Owner and Operator Manual

CHANGE HISTORY

DATE

DESCRIPTION

BY

6/1/2016

Issued

Preface

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

This manual provides important safety information, operating instructions, model specifications
and maintenance instructions for electric vehicles. It should be read completely before
attempting to drive or service the vehicle. Failure to follow the instructions in this manual could
result in property damage, severe personal injury, or death.

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.

1115 Commercial Ave • Reedsburg, WI 53959

Phone: [phone] • [phone] • Web: www.ColumbiaUSA.com

SU5-S/L

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TABLE OF CONTENTS – SU5

INTRODUCTION PAGE

SAFETY MESSAGES ..................................................................................................... 3

VEHICLE IDENTIFICATION NUMBER – PERSONAL TRANSPORT VEHICLE .............. 4

VEHICLE IDENTIFICATION NUMBER – LOW SPEED VEHICLE................................... 5

VEHICLE SPECIFICATIONS .......................................................................................... 6

SAFETY

GETTING STARTED ....................................................................................................... 7

SAFETY GUIDELINES .................................................................................................... 7

SAFETY VEHICLE STATEMENTS ................................................................................. 7

OPERATIONS AND CONTROLS

IMPORTANT FIRST STEP .............................................................................................. 9

INSPECTING THE VEHICLE .......................................................................................... 9

VEHICLE CONTROLS .................................................................................................... 10

KEYSWITCH ................................................................................................................... 10

DIRECTION SELECTOR ................................................................................................ 10

TURN SIGNAL/LIGHTS/HORN SWITCH ........................................................................ 11

WINDSHIELD WIPER/WASHER ..................................................................................... 11

PARKING BRAKE ........................................................................................................... 11

STEERING WHEEL ........................................................................................................ 12

HAZARD WARNING SWITCH ........................................................................................ 12

FUSE BLOCK – 12V ELECTRICAL CIRCUIT ................................................................. 12

FUSE BLOCK – 48V ELECTRICAL CIRCUIT ................................................................. 12

TILT BED ........................................................................................................................ 13

SECOND SEAT ............................................................................................................... 13

SECTION 4 ELECTRIC SYSTEM

BATTERY ACCESS ........................................................................................................ 13

IMPORTANT INFORMATION ......................................................................................... 13

MULTI-FUNCTION CLEARVIEW DISPLAY PANEL ........................................................ 14

MULTI-FUNCTION SMARTVIEW DISPLAY PANEL ....................................................... 16

WARNING LABEL & OPERATING INSTRUCTIONS ...................................................... 16

DRIVING THE VEHICLE ................................................................................................. 16

PRE-OPERATION CHECKLIST ...................................................................................... 16

BATTERY INSPECTION & MAINTENANCE ................................................................... 17

BATTERY CLEANING ..................................................................................................... 19

CONDITIONS WHICH AFFECT CHARGING .................................................................. 20

BATTERY CHARGING .................................................................................................... 20

CHARGER OPERATING INSTRUCTIONS ..................................................................... 21

CHARGER RECEPTACLE & REMOTE LED .................................................................. 21

RED LIGHT CHARGER ERROR CODES ....................................................................... 22

CHECK / CHANGE CHARGING ALGORITHM................................................................ 23

EXCESSIVELY DISCHARGED BATTERIES .................................................................. 24

TIPS FOR PROLONGING BATTERY LIFE ..................................................................... 24

BATTERY REMOVAL & INSTALLATION ........................................................................ 25

SINGLE POINT BATTERY WATERING SYSTEM .......................................................... 25

SU5-S/L

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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.

SERVICING YOUR VEHICLE

MAINTENANCE GUIDELINES ........................................................................................ 26

BRAKE SYSTEM ............................................................................................................ 26

BRAKE FLUID MAINTENANCE ...................................................................................... 26

TIRE CARE ..................................................................................................................... 26

WHEEL & TIRE REMOVAL/INSTALLATION ................................................................... 26

CLEANING ...................................................................................................................... 27

MAINTENANCE SCHEDULE - OWNER/OPERATOR..................................................... 27

MAINTENANCE SCHEDULE - QUALIFIED TECHNICIAN .............................................. 27

VEHICLE TROUBLESHOOTING .................................................................................... 28

CONTROLLER TROUBLESHOOTING ........................................................................... 28

SMARTVIEW DISPLAY FAULT CODES ......................................................................... 29

TOWING & TRANSPORTING

TOWING YOUR VEHICLE .............................................................................................. 31

TRANSPORTING YOUR VEHICLE ................................................................................. 31

VEHICLE STORAGE

BATTERY PREPARATION ............................................................................................. 32

VEHICLE PREPARATION .............................................................................................. 33

RETURNING VEHICLE TO SERVICE ............................................................................ 33

WARRANTY

LIMITED WARRANY COVERAGE .................................................................................. 34

RECORD OF SERVICE HISTORY AND DEALER CONTACT INFORMATION .............. 37

PERSONAL NOTES ....................................................................................................... 38

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.

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.

SU5-S/L

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Digit 1 thru 3 = Abbreviation (Model)

S5S (Short), S5L (Long)

Digit 4 = Power System

G = AC Drive, Induction Motor

Digit 5 = System Voltage

4 = 48V (8 – 6V)

M = AGM (8 -6V)

Digit 6 = VIN Spacer

- = Standard

# = Special Product

Digit 7= Controller Amperage

2 = 275 Amp
B = 450 Amp
D = 650 amp

Digit 8 = Brake System

V/R = HD F/R Hydraulic

Digit 9 = Build Year

Q = 2016, R = 2017, etc.

Digit 10 Thru 13 – Build Sequence

Ie…1234

VEHICLE IDENTIFICATION NUMBER – PERSONAL TRANSPORT VEHICLES (PTV)

Each PTV vehicle contains a unique Vehicle Identification Number (VIN) label. The VIN
describes facts and features of the vehicle and contains thirteen (13) digits. Figure 1-1 is an
example of a VIN label. VIN labels and can be found in several locations on the vehicle. One
location will be on the top of the dash panel on the driver’s side or under the steering wheel
cover as shown in Figure 1-2. Access to this location is by removing the three screws holding
the cover in place. A nameplate is also located in the front hood compartment and has important
information such as model, vehicle weights and rated capacity (load, operator and passenger)
as shown in Figure 1-3. Do not exceed this rated capacity.

Figure 1-1 Figure 1-2 Figure 1-3

VIN MATRIX Personal Transport Vehicle (PVT)

SU5-S/L

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Digit 1 thru 3:

5FC = CPC
Manufacturer Identification

Digit 4: Line

L = Low Speed Vehicle

Digit 5: Series

L = Summit Utilitruck

Digit 6: Body Type

2 = 2 Person
4 = 4 person

Digit 7: Engine Type

8 = AC Power System

Digit 8: Restraint

A = Type 1 Seat Belt

Assembly

B = Type 2 Seat Belt

Assembly (3 Point)

Digit 9: Check Digit

Calculated per 49CFR 565.4

Digit 10: Model Year

G = 2016
H = 2017 .

Digit 11: Plant Location

1 = Reedsburg

Digit 12-17: Sequential Numbers

00019 - 000999

VEHICLE IDENTIFICATION NUMBER LOW SPEED VEHICLES (LSV)

The VIN is printed on a white label, affixed to the top of the dash and affixed to the steering
wheel under the steering wheel cover (Figure 1-2). The VIN is also noted on the LSV Vin Label
(Figure 1-3) affixed to the bottom of the front hood area.

VIN MATRIX low Speed Vehicle (LSV)

SU5-S/L

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ITEM

SPECIFICATION

Battery Type:
Deep Cycle

48 Volt: 8 - 6 volt, heavy duty, 225 Ah minimum.

Brakes

Spring applied, auto-adjusting hydraulic drum on rear wheels,
front disc, foot operated parking brake.

Charger

Built in, micro-processor control, fully sealed, anti-drive away
interlock, 110-240 V AC, 50/60 Hz.

Directional Control

Rotary directional switch with FL (forward low), FH (forward
high), R (reverse) and N (neutral).

Drive

Direct coupled to oil bath, helical geared.

Motor

5 KW or 8 KW AC Brushless.

Rear Axle

10.37:1 or 16.77:1 helical gear reduction with integral
differential.

Speed Controller

Programmable, solid state, reduced speed reverse with
diagnostic calibrator interface and display panel.

Steering

Automotive rack and pinion.

Tire PSI

32 psi

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

VEHICLE SPECIFICATIONS

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

SU5-S/L

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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,
severe personnel injury or death.

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.

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 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-driving rules.

VEHICLE SAFETY STATEMENTS

SU5-S/L

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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. These basic rules of operation, combined with courtesy
and common sense, will help make driving your Columbia vehicle a safe and pleasant
experience.

All vehicles should only 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 engage 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, instead use service brake pedal.
Make sure directional switch is in position for the desired direction of travel before

depressing the accelerator. Do not change the directional switch while vehicle is
moving.

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

Do not operate while under the influence of alcohol or drugs.

Personal Transportation Vehicles are not Federal or State DOT approved and are 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.

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.

SU5-S/L

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

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.

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.

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

before watering.

INSPECTING THE VEHICLE

After battery charging, perform an inspection of the vehicle 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 (32 psi

recommended). 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.
 Check steering for responsiveness and minimal play.

 Key can only be removed when keyswitch is in the “OFF” position.

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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.

KEYSWITCH

This is a five position automotive type
switch and is located on the right side of the
steering column. The first key position is
OFF and is marked S. The second is an
accessory position marked A which is not
used. The third position is not marked and
is not a key stop. It is not used. The fourth
position marked M is the ON and powers up
the vehicle. The last position marked D is
not used. If the key is rotated to this
position the vehicle power will be reset.

Turning the keyswitch to OFF is highly
recommended whenever vehicle is not in
use. Always remove the key out from the
keyswitch when leaving the vehicle.

DIRECTION SELECTOR

Selector is located between the seats. In

the middle position the vehicle’s direction

signal is turned OFF or in neutral. Turning
the selector to the right from the middle
position moves the vehicle in forward
direction (high & low speeds). Turning the
direction selector to the left moves the
vehicle in the reverse direction. A warning
buzzer sounds when in reverse.

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

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

VEHICLE CONTROLS

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TURN SIGNAL/LIGHTS/HORN SWITCH

The horn is activated by pushing in the
button at the lever (A.). Moving lever up or
down will activate the turn signals. A green
light on the dash will flash indicating the
turning direction. The headlights and
taillights are activated by a three position
selector (B). OFF is the bottom position,
middle activates the parking and tail lights,
and the upper position activates the
headlights. High and low beams are
selected by pulling back on the lever.

WINDSHIELD WIPER/WASHER

Wiper switch is located on the right side of
the steering console. Wipers have four up
positions:

3 High Speed
2 Slow Speed
1 Off
0 Off

Pulling lever towards you activates the
washer fluid. Pushing the switch down

activated a “quick” wipe. The fluid reservoir

is located under the front hood.

NOTICE: To avoid scratching the
windshield always apply fluid before
wiping.

PARKING BRAKE

Shown is the parking brake pedal and the
parking brake release lever. Each operate
in the same manner as a conventional
automobile.

Always apply the parking brake when
leaving the vehicle. It should be firmly
pressed and locked to prevent the vehicle
from rolling. It remains applied until
released by lifting the lever.

If the parking brake is left engaged when
the accelerator pedal is pressed, the unit
will display a fault on the display panel and
will not operate until released.

SU5-S/L

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