Columbia CR-10 Chariot Operator`s manual

Owner’s
and
Operator’s
Manual
CR-10
Chariot
Electric
Vehicles
PN 709642-03
5/2011
Preface
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: (608) 524-8888 • Fax: (608) 524-8380
(800) 222-4653 • Web: www.parcar.com
i
TABLE OF CONTENTS
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
2.5 LIFTING INSTRUCTIONS
2.6 BATTERY DISCONNECT METHODS
2.7 BATTERY REMOVAL AND INSTALLATION
3.0 OPERATIONS AND CONTROLS
3.1 INSPECTING THE VEHICLE
3.2 WHAT TO DO IF YOU HAVE A PROBLEM
3.3 VEHICLE CONTROLS
3.3.1
KEYSWITCH
3.3.2
BATTERY STATE OF CHARGE METER
3.3.3
HORN BUTTON
3.3.4
CHARGER RECEPTACLE
3.3.5
LOW BATTERY RESET SWITCH
3.3.6
CHARGING STATUS LIGHTS
3.3.7
WARNING LABEL AND OPERATING INSTRUCTIONS
3.3.8
FOOT TREADLE PLATFORM
3.3.9
STEERING HANDLE BARS
3.4 VEHICLE OPERATING INSTRUCTIONS
3.4.1
DRIVING THE VEHICLE
3.4.2
PARKING
3.4.3
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 CHARGING
4.5.1
CHARGER INFORMATION
4.5.2
CHARGER OPERATING INSTRUCTIONS
4.5.3
LOW BATTERY RESET SWITCH
4.5.4
TROUBLE SHOOTING CHART
4.6 SPECIFIC GRAVITY TEST
4.7 TIPS FOR PROLONGING BATTERY LIFE
4.8 VEHICLE TROUBLESHOOTING
5.0 SERVICING YOUR VEHICLE
5.1 MAINTENANCE GUIDELINES
5.2 BRAKE SYSTEM
5.3 CLEANING
5.4 MAINTENANCE SCHEDULE - OWNER/OPERATOR
5.5 MAINTENANCE SCHEDULE - QUALIFIED TECHNICIAN
6.0 VEHICLE STORAGE
6.1 BATTERY PREPARATION
6.2 VEHICLE PREPARATION
6.3 RETURNING VEHICLE TO SERVICE
ii
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.
DATE
5/9/2011
CHANGE HISTORY
DESCRIPTION
Issued – separated from Parts & Service
iii
BY
TB
1.0 INTRODUCTION
This manual provides important safety information, operating instructions, model specifications and
maintenance instructions for the CR-10 Chariot.
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.
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.
1.2 VEHICLE DESCRIPTION
The Chariot is a single passenger vehicle involving stand-up operation. This vehicle is designed to be
driven on smooth surfaces in and around industrial plants, nurseries, institutions, motels, mobile home
parks, and resorts.
This vehicle is not designed to be driven 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 1993 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 can be found in two locations.
The VIN is recorded on the vehicle nameplate which is located on
the left side of the operator’s position. See Figure 1.3.1.
The nameplate also has other important information such as vehicle
weights and capacity. Do not exceed this capacity. This rated
capacity includes cargo and operator.
Figure 1.3.1
1-1
The VIN is also stamped on the metal cross bar located under the
foot treadle platform. See Figure 1.3.2.
To ensure prompt service when repairs or adjustments are
required, your Columbia Dealer must have the VIN.
Figure 1.3.2
CR1A1-0ZG1234 is an example of a current VIN.
For your own personal reference, fill in the VIN in the space provided below.
1.4 VIN MATRIX
13 DIGIT VIN – USED AFTER FEBURARY 2006
CR1 (CR-10 Chariot)
A = Series, Resistor
1 = 12V
- = normal
# = Special Product
0 = Not Applicable
Z = Rear Mechanical
H = 2009, J = 2010, K = 2011 etc.
(Letters I & O not used)*
1234
Digit 1 thru 3 = Abbreviation (Model)
Digit 4 = Power System
Digit 5 = System Voltage
Digit 6 = VIN Spacer
Digit 7= Controller Amperage
Digit 8 = Axle/Brake System
Digit 9 = Build Year
Digit 10 Thru 13 – Build Sequence
1.5 VEHICLE SPECIFICATIONS
Passenger Capacity
1
Max. Speed (MPH)
9
Turning – Curb to Curb (in)
79
Turning –Intersecting Aisle (in)
41
Overall Length (in)
52
Overall Width (in)
29.5
Overall Height (in)
44
Wheelbase (in)
36
Load Bed Height (in)
24
Load Bed – LxW (in)
18x16
Tires
4.80x8, Pneumatic, 6 ply, Load Range C
4.80x8, Foam Filled, 6 ply, Load Range C
1-2
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
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
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.
Do not overload the vehicle. Never exceed maximum payload as specified on the vehicle
nameplate. See Section 1.3, Figure 1.3.1.
2-1
Your safety and the safety of others depend on your safe operation and maintenance of this vehicle. Prior
to operation, you, the operator, must be thoroughly familiar with this and all other sections of this manual.
2.3 SAFETY WARNINGS
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.

Never exceed the capacity ratings of the vehicle. Exceeding these limits may endanger
occupant or cause vehicle damage.

Completely stop vehicle before stepping off.

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.

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.
2.4 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.
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.
2-2
2.5 LIFTING INSTRUCTIONS
Use extreme caution lifting or working on or around lifted vehicle. Vehicle should be on a flat,
hard and level surface.
When lifting the vehicle for service, remove key and use a sturdy lifting device such as a hoist or floor jack
placed under the Chariot body. Always block wheels to prevent it from rolling. After the body is lifted 4 to
6 inches from the floor, place a suitable device under vehicle frame to support vehicle weight. An example
is a 4” x 6” wooden block.
If vehicle is raised while loaded, check that the load is secured before lifting. Failure to do so
could cause damage to the vehicle, the load or cause personal injury.
2.6 BATTERY DISCONNECT METHODS
Figure 2.6.1 illustrates the battery configuration. Disconnect both leads before performing any
maintenance.
Figure 2.6.1
2.7 BATTERY REMOVAL AND INSTALLATION





Remove battery negative (-) cable.
Remove battery positive (+) cable.
Remove battery hold down.
Remove batteries from vehicle.
To install batteries, reverse the removal procedure with the negative (-) cable being attached last.
2-3
3.0 OPERATIONS AND CONTROLS
3.1 INSPECTING THE VEHICLE
Upon receipt 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.
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. Check
that battery connections are tight and all cells are filled to above plates. Check for damaged or leaking
batteries.
Inspect 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.
Check the body and other 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.

Foot Treadle

Steering Handle Bar
NOTICE: Each control should operate smoothly and easily without sticking or requiring
excessive effort.
Check that the horn sounds and that the key can only be removed when keyswitch is in the “OFF”
position.
3.2 WHAT TO DO IF YOU HAVE A PROBLEM
If vehicle has just been delivered, report any physical damage or missing items to the shipping company
and your local Columbia Dealer.
Report any service issue problems to the individual(s) responsible for correction and/or repair or contact
your local Columbia Dealer for service.
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.
3-1
3.3 VEHICLE CONTROLS
This section describes the operating controls of the vehicle. Figure 3.3.1 identifies the locations of many
of these controls.
G
H
F
A
E
B
D
C
Figure 3.3.1
3.3.1 KEYSWITCH – Figure 3.3.1 Arrow A
The keyswitch energizes the vehicle. Rotate the key to the right from vertical to turn the vehicle on, return
to vertical to turn the vehicle off.
If equipped, the keyswitch can also have a reverse direction. Rotate the key to the left from vertical to
move in reverse (REV).
NOTICE: Do not shift from forward to reverse or vice-versa while the vehicle is in motion. Make
sure the vehicle is completely stopped before changing direction.
To avoid injury, speed in reverse should always be kept at a minimum.
The keyswitch should be in the vertical OFF position whenever the operator leaves the vehicle. The
switch is also designed to secure and disable the vehicle. You can remove the key only when the key
switch is in the OFF position.
3.3.2 BATTERY STATE OF CHARGE METER - Figure 3.3.1 Arrow B
The battery state of charge meter is an analog gauge with an indicating needle and a colored
background. It is a continuously reading meter. At rest with fully charged batteries the meter should read
in the right white region.
3-2
When accelerating quickly, the needle will move to the left green region near the very far left red region.
This is normal. If the needle continues past the green region into the very far left red region, it indicates
that the batteries need recharging as soon as possible to avoid a shut-down of the vehicle.
3.3.3 HORN BUTTON – FIGURE 3.3.1 Arrow C
The horn button is located on the left inside body panel and may be sounded by applying lateral pressure
with the operator's left leg.
3.3.4 CHARGER RECEPTACLE – Figure 3.3.1 Arrow D
The charger receptacle is for battery charging using the supplied AC cord.
3.3.5 LOW BATTERY RESET SWITCH – Figure 3.3.1 Arrow E
The Low Battery Reset Switch is used if the battery is heavily over discharged. See Section 4.5.3.
3.3.6 CHARGING STATUS LIGHTS– FIGURE 3.3.1 Arrows F
These lights indicate the battery charging status.
3.3.7 WARNING LABEL and OPERATING INSTRUCTION - Figure 3.3.1 Arrows G & H
Read the warning label and operating instruction information carefully before operating the vehicle.
Do not remove any nameplate, warnings, or instructions affixed to your Columbia Vehicle.
Promptly replace any that become damaged or removed. Contact Columbia ParCar for
replacements.
3.3.8 FOOT TREADLE PLATFORM – Figure 3.3.2 Arrow A
The foot treadle platform controls acceleration and
braking. By slowly tilting the treadle forward (weight on
toes) the accelerator is engaged and vehicle moves
forward. By tilting the treadle backward (weight on
heels) the brake is applied.
A
NOTICE: Do not stomp down on the rear of
treadle.
The parking brake is spring loaded to set automatically
when leaving the vehicle and is automatically
disengaged by tilting the treadle forward.
Figure 3.3.2
3.3.9 STEERING HANDLE BARS – NOT SHOWN
The steering system is designed to operate as a bicycle does. The vehicle will turn to the same direction
as the handle bar.
Be sure to have both hands on the handlebars at all times.
Do not turn the vehicle sharply at high speeds.
3-3
3.4 VEHICLE OPERATING INSTRUCTIONS
3.4.1 DRIVING THE VEHICLE















Do not operate vehicle unless you are a qualified and trained operator.
Keep the vehicle under control at all times.
Drive only on level surfaces or on surfaces having an incline of no more than 10%.
Drive slowly when making a turn, especially if the ground is wet, slippery or when driving on an
incline.
Do not drive this vehicle in hazardous areas unless this vehicle is approved and labeled for such
operation.
Do not drive over loose objects, holes or bumps.
Observe all traffic regulations and speed limits.
Keep to the right of traffic under normal conditions.
Maintain a safe distance from all objects and other vehicles.
Yield right of way to pedestrians, ambulances, fire trucks or other vehicles in emergencies.
Do not overtake another vehicle at intersections, blind spots or other dangerous locations.
Keep a clear view ahead at all times. Slow and sound the horn when approaching a corner or other
blind intersection.
Immediately report any accident or vehicle problem to your supervisor.
Do not load cargo that can easily fall off this vehicle.
Do not exceed the cargo load capacity of this vehicle.
3.4.2 PARKING



If you will be away from this vehicle turn off the keyswitch, remove the key and take the key with you.
If you park this vehicle on an incline, block the wheels.
Do not block fire aisles, fire equipment, or stairways.
3.4.3 PRE-OPERATION CHECKLIST
Before operating the vehicle always inspect the items listed in the following checklist. Should
any item malfunction or need adjustment. Do not operate vehicle until the problem has been
corrected.
ITEM
PROCEDURE
Fully charged or adequately charged to provide power for duration of
operations.
The AC cord is disconnected from the vehicle.
Batteries
Electrolyte level in each cell covers the top of cell plates.
Batteries are secure and free of corrosion.
All terminals and connections are tight.
Tire Pressure
Inflated to the specifications labeled on the tire sidewall.
Horn
Press horn button to sound horn.
Treadle
Operates smoothly
Labels
All warning and operation labels in place.
Steering
Responsiveness and the absence of excessive free play.
Cargo
Secured to the bed platform.
Load is balanced and not top heavy.
Obstacles
Path of intended travel is free for obstructions.
3-4
4.0 ELECTRIC SYSTEM
4.1 IMPORTANT INFORMATION
The type of battery used in a Columbia vehicle has a service requirement which is quite different from that
of an automotive battery.
The electric vehicle battery supplies all of the power to drive the vehicle. During operation the power
stored in the batteries is expended. While the amperage drain rate can vary greatly depending on the
type of service, the duration of use and the number of "starts" and "stops" made during a day, the
batteries nevertheless progress through each duty cycle from "fully charged" to an almost depleted state.
This type of service is known as "deep cycle" service and electric vehicle batteries are specifically
designed to handle this type of service.
Proper performance of your Columbia Vehicle can only be obtained from specified deep cycle, electric
vehicle batteries.
PLEASE REVIEW IMPORTANT DANGER STATEMENTS WHEN WORKING AROUND BATTERIES
AND CHARGING SYSTEMS!
Always remove key and disconnect batteries before servicing or repairing the vehicle (Section
2.6).
Always wear full-face shield when working on or near batteries.
All batteries used in electric vehicles can explode! Batteries produce explosive hydrogen gas at
all times, especially, during charging or discharging. Ventilate area when charging batteries.
Do not attempt to charge a battery if it is frozen, or if the case is bulged excessively. Frozen
batteries can explode!
Properly dispose of the battery.
Do not smoke around batteries. Keep sparks and flames away from batteries and the charging
area.
When working around or servicing batteries use care to prevent an accidental arc which could
cause an explosion.
Use only approved insulated tools, remove jewelry such as rings, watches, chains etc. and
place an insulating material (wood, plastic, rubber etc.) over all battery connections.
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.
Battery acid is poisonous and can cause severe burns. Avoid contact with skin, eyes, or
clothing.
ANTIDOTES
EXTERNAL: Flush with water. Call a physician immediately.
INTERNAL: Drink large quantities of milk or water. Follow with milk of magnesia or vegetable
oil. Call a physician immediately
EYES: Flush with water for fifteen minutes. Call physician immediately.
4-1
NOTICE: Automotive batteries should never be used for "deep cycle" application, as their
useful life will be very short.
Install surge arrestors on incoming AC power lines. Surge arrestors will help protect
electrical/electronic components in the charger and vehicle from all but direct or “close
proximity” lightning strikes.
Damaged or corroded battery terminals should be replaced or cleaned as necessary. Failure to
do so may cause overheating during operation.
Do not attempt to recharge batteries with a charger not designed for your vehicle.
Only trained technicians should service the CR-10 charger. Contact your Columbia Dealer for
assistance.
4.2 BATTERY INSPECTION & MAINTENANCE
Check the electrolyte level on new batteries before they are put into service, and, at a minimum, once a
week thereafter. Water use increases as batteries age.
See Figure 4.2.1. Never allow the electrolyte level (A) to fall below the top of the plates (C). If the plates
are exposed, add only enough to cover the plates before charging. After batteries are fully charged, fill
cells to just below the bottom of the cell vents (B). Electrolyte level should not touch the bottom of the cell
vents.
Figure 4.2.1
Do not overfill batteries. Electrolyte expands and can overflow during charging. Water added to replace
the spillage dilutes the electrolyte and reduces its specific gravity.
Use only distilled water. Vehicle batteries may use up to 16 quarts of water during their useful life and
non-distilled water may contain harmful minerals which will have a cumulative adverse effect on battery
performance and life.
Batteries and connections must be clean and dry. See Section 4.3.
Be sure battery hold downs are properly tightened. A loose hold down may allow the battery to become
damaged from vibration or jarring. A hold down that is too tight may buckle or crack the battery case.
Weekly inspect battery posts, clamps and cables for breakage, loose connections and corrosion. Replace
any that are damaged. Check to see that battery cap vent holes are clear. Plugged vent holes will not
permit gas to escape from the cell and could result in battery damage.
4-2
4.3 BATTERY CLEANING
Acid-soaked dirt on the battery terminal connections causes current leakage, reduces battery efficiency,
and battery life.
Check that all vent caps are tightly in place before washing.
Hose wash battery terminal connections periodically with clean low-pressure water to keep them free of
acid spillage, dirt, and other debris. Do not hose wash switches, solenoids and other electrical control
devices. Cover as necessary to prevent splashing.
Clean battery terminal connections with baking soda (sodium bicarbonate) and water solution (5
teaspoons baking soda per quart water) and stiff bristle brush. Rinse with clean water and dry with a
clean cloth. Do not allow solution to enter cap vent holes.
NOTICE: Follow local ordinances and codes for proper disposal of battery cleaning waste.
4.4 CONDITIONS WHICH AFFECT CHARGING
Always schedule enough charging time to allow the batteries to become fully charged. Charging time is
affected by age and battery condition, state of discharge, electrolyte temperature, AC line voltage, and
other variables. Correct charging methods extend battery life and vehicle range between charges.
New batteries need up to four hours more charging than “mature” batteries. Before the first use,
completely charge new batteries. Charging time will vary based on conditions noted above but will
probably be 6 to 10 hours.
If vehicle is used only occasionally, a refresher charge should be given prior to using.
Battery efficiency is affected by temperature. If the temperature of the outside air and/or batteries is
below 60º F, battery capacity is reduced. Batteries will require more frequent and longer charge periods in
early spring, fall and winter.
As batteries age, they finish charge at progressively higher charge rates and tend to use more distilled
water. At this point in battery age, charger will automatically begin reducing charge time.
Batteries found defective must be replaced. All batteries in a vehicle should be matched according to age,
capacity and brand.
4.5 BATTERY CHARGING
4.5.1 CHARGER INFORMATION
The built-in battery charger is custom made for Columbia vehicle CR-10 Models. Its operation is totally
automatic. When connected to a 110 - 120 Volt AC power source, the charger's electronic timer will turn
the charger on. It determines and provides the energy necessary to return batteries to a fully charged
state, automatically shutting off when the batteries are fully charged. This occurs when each cell reaches
approximately 2.5 volts.
4.5.2 CHARGER OPERATING INSTRUCTIONS
Plug 120 volt AC supply cord into charger receptacle on charger panel. After a short time delay of
approximately 5 to 6 seconds, a RED light comes on indicating battery charging.
When the solid state circuitry senses that the batteries are fully charged, the RED light turns off and the
GREEN light turns on indicating that charging is complete.
The GREEN light will remain on until the AC cord is disconnected. At that point the light will turn off and
the charger will reset itself for the next charging cycle.
4-3
4.5.3 LOW BATTERY RESET SWITCH:
This is used if the batteries are heavily over discharged. When the AC cord is connected, the RED light
will turn on but will shortly turn off. To reactivate the charger, push the reset button for 10 seconds. This
will restart the charger. Release the button and the charger will continue to charge.
4.5.4 TROUBLE SHOOTING CHART
Symptom
No transformer hum
Transformer
hums,
ammeter deflection
but
no
AC fuse keeps blowing
Charger output low or battery not
getting charged
Charger not shutting off
Repair or Replace
AC Fuse
AC Input Cord
Loose wires on auto-start control
Primary of transformer
Auto-start control
DC fuse
DC connector shorted or open diode
Defective ammeter
Shorted AC cord
Shorted primary of transformer
Defective capacitor
Resonant of transformer
Open diode
Loose wires on auto-start
Defective auto-start
4.6 SPECIFIC GRAVITY TEST
It is possible to determine a battery's ability to perform by measuring the specific gravity (sp. gr.) of each
cell with a hydrometer. This is the best method to determine a defective battery.
The hydrometer readings indicate two things:

State of Charge - The amount of electrical power stored in the battery.

Condition - The ability of battery to store and deliver power.
NOTICE: Batteries should be fully charged before performing specific gravity tests to determine
battery condition. Hydrometer tests of batteries not fully charged are misleading and
inconclusive.
There are different type hydrometers. Carefully read and follow the instructions supplied with your
hydrometer.
4.7 TIPS FOR PROLONGING BATTERY LIFE
To prolong battery life, recharge batteries as soon as they become 20% or more discharged (less than
1.238 sp. gr.). Batteries may be recharged if vehicle has been driven 15 minutes or more since the
previous charge.
Do not allow batteries to fall below 80% discharge (1.098 sp. gr.). Deep discharging significantly reduces
battery life. Opportunity charging during breaks or shift change can be used to extend range but always
complete a full charge cycle at least once a day.
If the vehicle is not operated daily the Power keyswitch should be turned off. This will reduce power loss
on the batteries.
Batteries in storage may self discharge and should be recharged when the specific gravity falls below
1.238 sp. gr.
NOTICE: Specific gravity readings are at 800F. Values need adjustment for electrolyte
temperature. Reduce .004 for every 100F below 800F. Increase by that amount for every 100F
above
4-5
4.8 VEHICLE TROUBLESHOOTING
PROBLEM
CHECK
Keyswitch on.
Keyswitch is in desired direction.
Keyswitch for loose wires or faulty switch.
Will not move
Batteries for loose terminals, corrosion, electrolyte level or state of charge.
Motor for loose wires, open circuits.
Batteries for loose terminals, corrosion, electrolyte level or state of charge.
Brakes dragging
Runs slow
Under inflated or flat tires.
Wheels for binding, do not spin freely.
If these test procedures do not resolve your vehicle problem, contact your Columbia Dealer for service.
4-6
5.0 SERVICING YOUR VEHICLE
5.1
MAINTENANCE GUIDELINES
To ensure that the vehicle is kept in a safe and correct operating condition, it must be inspected and
maintained on a regular basis. Proper lubrication, electrical control adjustments, safety feature checks,
etc. performed at recommended intervals will help prevent damage or failure of the unit while providing
optimum performance.
Follow the guidelines below to assure proper maintenance.











Allow only trained maintenance personnel to maintain, repair, and inspect the vehicle.
Before starting any repairs or maintenance, immobilize the vehicle by turning the power keyswitch off
and removing the key.
Disconnect both of the main battery pack leads before working on or disconnecting any electrical
component or wire.
Block the chassis with jack stands before working under a raised vehicle.
Conduct vehicle performance checks in an authorized area where a safe clearance exists.
Before starting the vehicle, follow the recommended safety procedures in Chapter 2, (SAFETY).
Avoid fire hazards and have fire protection equipment present in the work area.
Do not use flammable fluids for cleaning parts.
Work in a properly ventilated work area.
Regularly inspect and maintain in safe working condition the brakes, steering mechanisms, speed
and directional control mechanisms, warning devices, guards and safety devices.
Keep the vehicle in a clean condition to minimize fire hazards and facilitate detection of loose or
defective parts.
5.2 BRAKE SYSTEM
The mechanical brakes consist of two rear drum
brakes. With no force applied to the treadle, brakes
are properly adjusted when the back edge the treadle
is approximately even with the top edge of the rear
frame crossbar. See Figure 5.2.1.
Figure 5.2.1
To adjust the brakes (See Figure 5.2.2):

Loosen jam nut (Arrow A) on upper end of the
treadle to brake linkage.

Turn (lengthen) upper brake linkage (Arrow B)
and check adjustment.

Once properly adjusted and tighten the jam nut.
A
NOTICE: Minimum brake shoe lining thickness
is .080 inches.
B
Figure 5.2.2
5-1
5.2 CLEANING
Wash underside to remove all dirt and debris. Do not direct high pressure water at the speed switch or
tops of the batteries.
Wash body and seat with a mild detergent. Do not use abrasives (bodies are painted). Frequent washings
with mild soap will preserve the finish of your vehicle. For stubborn and imbedded dirt, a soft bristle brush
may be used. Tar, asphalt, creosote and the like should be removed immediately to prevent staining of
paint.
NOTICE: Do not use harsh detergents, abrasives or cleaning solvents that contain ammonia,
aromatic solvents or alkaline material to clean cab.
Lug nuts tight.
*
Check tire pressure, wear, damage. Dented rims.
*
SemiAnnual
Operation
Monthly
Item
Weekly
5.3 MAINTENANCE SCHEDULE - OWNER/OPERATOR
Tires
Electrical
Brakes
Body and
Frame
Lube
Check electrolyte level.
*
As required, clean battery terminals and wash cases.
*
Check the general condition of the electrical system
(connections, frayed/broken cables).
*
Adjust.
*
Inspect for loose hardware (bolts & nuts).
*
Clean body and seats, Wash as needed.
*
Wash engine/motor compartment and undercarriage.
*
Oil movement points (body hinges, brake mechanisms and
linkage, leaf spring bushings etc.).
5-2
*
5.4 MAINTENANCE SCHEDULE - QUALIFIED TECHNICIAN
Drive
Electrical
Brakes
Control
Speed
Lube
Steering
Check treadle adjustment, motor
mounting hardware, and drive chain
adjustment
Test batteries
Inspect motor condition and operation.
Inspect brakes – clean, adjust, replace
as needed.
Adjust brakes
Lubricate
Check contact bars for wear, spring
tension
Rear wheel bearings, grease or replace
Annual
*
*
*
*
*
*
*
*
Repack front wheel bearings
Check front wheel bearing adjustment
*
Check fork spindle bearing adjustment
*
5-3
SemiAnnual
Quarterly
Operation
Monthly
Item
Weekly
It is recommended that the following be performed by a trained qualified technician or your Columbia
Dealer
*
6.0 VEHICLE STORAGE (over 6 weeks)
6.1 BATTERY PREPARATION
Before storage make sure batteries are fully charged and the electrolyte is full in all cells per Section 4.2.
Clean the batteries and connections per Section 4.3.
Recharging will be necessary during storage. Frequency for recharging is as follows:
STORAGE TEMPERATURE
0
CHARGE AT
0
Below 4 C (40 F)
0
0
0
Every 6 months
0
4 C - 16 C (40 – 60 F)
Every 2 months
0
Once a month
0
Above 16 C (60 F)
The specific gravity of the electrolyte should be checked every 6 to 8 weeks using a hydrometer. See
Section 4.6.
The batteries should be recharged as necessary to a specific gravity of approximately 1.260 sp. gr. After
charging, disconnect the batteries. See Section 2.6.
Batteries in a low state of charge will freeze at higher temperatures than fully charged batteries.
Do not attempt to charge a battery that is frozen or if battery case is excessively bulged. Frozen
batteries can explode. Properly dispose of the battery.
Table C indicates freezing points of batteries at different specific gravities.
TABLE C
FREEZE POINT OF/OC
-70/-57
-39/-38
-16/-26
-2/-19
+17/-8
SPECIFIC GRAVITY
1.260
1.230
1.200
1.117
1.110
NOTICE: Specific gravity readings are at 800F. Values need adjustment for electrolyte
temperature. Reduce .004 for every 100F below 800F. Increase by that amount for every 100F
above
6.2 VEHICLE PREPARATION




Store the vehicle in a cool place.
Maintain tire pressure at sidewall recommendation.
Clean vehicle body, battery compartment and vehicle underside.
Block wheels to prevent movement.
NOTICE: Make sure keyswitch is in the OFF position.
6.3 RETURNING VEHICLE TO SERVICE



If necessary, connect the battery pack and fully recharge batteries.
Check tire pressure and readjust if necessary.
Perform the pre-operation checks per Section 3.4.4.
6-1
1115 Commercial Avenue • Reedsburg, WI 53959
Phone: (608) 524-8888 • Fax: (608) 524-8380
(800) 222-4653 • Web: www.parcar.com