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OPERATOR’S MANUAL

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Summary of Contents for Journeyman

Page 1: ...OPERATOR S MANUAL ...

Page 2: ...OUND YOU THE HIGHER THE RISK OF INJURY To reduce these risks Obey all traffic regulations Avoid roads with regular traffic even if the speed limit is low Whenever possible stay on roads and lanes limited to low speed vehicles Wear your safety belts at all times Avoid operating the vehicle at night because your vehicle may be hard for others to see To reduce the chance of the vehicle tipping over r...

Page 3: ...afety seat Do not use or install child safety seat in any seat or position in the vehicle Always obey and follow laws and regulations regarding the transportation of children Children that require the use of a child safety seat in a regular type automobile should not be transported in this vehicle ...

Page 4: ...tion contained in this document is subject to change without obligation to make these changes on units previously sold IMPORTANT OPERATING NOTES ALWAYS OPERATE YOUR JOURNEYMAN IN COMPLIANCE WITH YOUR STATE AND LOCAL VEHICLE REGULATIONS INCLUDING REGISTRATION TITLING INSURANCE SEAT BELT USAGE AND OPERATOR S LICENSING SWITCH VEHICLE TO OFF POSTION REMOVE KEY AND SET PARKING BRAKE PRIOR TO EXITING DR...

Page 5: ...Dome Light 7 Glove Box 7 Brake Pedal 7 Accelerator Pedal 7 Battery Discharge Indicator BDI 8 Turn Signal Switch 9 Horn 9 Headlamp Operation 9 Windshield Wiper 10 Speedometer Odometer 10 Fuse Box 10 Safety Belts 11 Pre operation Inspection 12 Operation Inspection 13 Driving Instructions 14 Towing 15 Storage 16 Maintenance 17 Scheduled Maintenance 18 Battery Care 20 Charging 23 Cleaning and Appearan...

Page 6: ...icle or attempting repair work Any violations of instructions in the manual may lead to property loss serious injury or even death Pay special attention to important statements with the words such as Danger Warning Attention etc If any of the operation warning decals are damaged defaced destroyed or illegible it is important that they be replaced with new decals Please contact the manufacturer or ...

Page 7: ... seek appropriate shelter immediately Inspect battery terminals cables and batteries before each use Always wear a full face shield rubber gloves and rubber apron when working with or in close proximity to batteries Turn the ignition switch to the off position remove the key unplug the charger and place the run tow switch to the tow position before inspecting or performing any type of service on t...

Page 8: ... work turn the run tow switch to the middle position see figure 1 Turn off the vehicle while preforming any type of maintenance or repairs Figure 1 Run Tow switch in middle position 3 Use only insulated tools to handle the battery pack and electrical components Remove all jewelry and loose items before performing maintenance procedures 4 Improper application or maintenance will lead to deteriorati...

Page 9: ...Journeyman Operator s Manual APPEARANCE OF THE E MERGE CONTROLS Page 4 ...

Page 10: ...rn the direction selector switch forward reverse until the vehicle has come to a complete stop Key Switch The key switch is located on the right side cover of the steering stem and has two positions OFF ON The key can only be removed in the OFF position High low speed switch See figure 6 The high low speed switch is located on the right side cover of the steering stem OFF Figure 4 ON Figure 5 Figu...

Page 11: ...EV for Reverse and a Neutral toggle position located halfway between the forward and reverse positions Headlight Switch The Headlight Switch is located on the left side of the steering stem See Figure 10 Emergency Hazard Light Switch The Emergency Hazard Light Switch is located on the dashboard See Figure 11 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Page 6 ...

Page 12: ...e Journeyman wheels for shorter stopping distances To slow the vehicle down the operator should depress the brake pedal Accelerator Pedal The accelerator pedal is the smaller pedal to the right of the brake pedal When depressed the accelerator pedal will engage the drive motor in the direction the FWD REV switch is set The vehicle will accelerate up to its top speed of just under 25 mph at which t...

Page 13: ...er has 10 indicator lights When the light bar is at the top of the indicator the battery pack contains a full charge When the battery discharge is down by 70 the two remaining lights will flicker as a warning When the vehicle is at 80 discharge reduced performance will occur indicating the immediate need to recharge the batteries Continued operation beyond this discharge state will result in reduc...

Page 14: ... The turn signal stalk will not automatically return to the off position after turn the operator should manually move the stalk to the center position upon completing each turn Horn To activate the horn the operator should press the end of the stalk Headlamps Turn on the master headlamp switch See page 6 Figure 10 to activate the headlamps Pulling the multi function stalk down will initiate the lo...

Page 15: ...25 mph The gauge will also record the total distance traveled Within the speedometer is a trip odometer which can be set by depressing the set buttons This feature is especially useful in measuring the distance between each charge cycle The reading of the speedometer can be programmed to read out in either in miles or kilometers To change the display simply press and hold the small button on the l...

Page 16: ...ull the metal tab out away from the retractor and insert into one of the two buckles located near the center of the seat A click will be heard when the tab is securely latched Position the lap belt as low as possible on the hips not the waist Properly adjust and ensure a snug fit by pulling the shoulder portion forward The retractor will lock the belt during sudden stops It may also lock if the pe...

Page 17: ...oughly inspected by both the manufacturer and dealer Before the initial operation it is important that the user inspect the vehicle using the following guidelines General Check all parts are securely fastened to the vehicle no parts are missing and all screws or nuts are properly tightened Decals Review all warning decals and placement on the vehicle Safety Belts Visually inspect and test for safe...

Page 18: ... the steering wheel General listen for any unusual noises such as squeaks or rattles Check the vehicle s ride and performance Have a certified Columbia Dealer or authorized technician investigate anything unusual GENERAL OPERATION Automatic Parking Brake with the run tow switch in the run position the Journeyman s motor will inhibit the vehicle from rolling until the accelerator is depressed Motor...

Page 19: ... sure you use headlamps and tail lamps Bring the vehicle to a complete stop prior to shifting between FWD REV Failure to do so may injure an unsuspecting passenger and or damage to the vehicle Operate the vehicle from the driver s seat only To help prevent the risk of serious injury driver and passenger should keep all body parts inside the vehicle at all times To reduce the chance of the vehicle ...

Page 20: ...tteries and motor TOWING Do not tow behind an automobile or truck on any public roads To tow the vehicle on public roads use a trailer with a minimum load rating of 1 500lbs To tow the vehicle turn the ignition switch to the off position and place the FWD REV switch in neutral Place the Run Tow switch located under the seat to the tow position Do not exceed 5 mph 8 kph Use extreme caution while tu...

Page 21: ...vehicle and disconnect the batteries 3 Dirty battery tops can conduct small amounts of electricity and hasten the discharging of the batteries Clean battery tops and terminals with a solution of water and baking soda 1 gallon of water for 1 cup of baking soda Do not allow this solution to enter the batteries 4 Inspect and clean battery wires Damaged or frayed wires should be replaced 5 Store the v...

Page 22: ...C Wear proper safety apparel while operating the vehicle Proper safety apparel includes but is not limited to safety goggles or approved eye protection insulated gloves and a face mask D Remove all jewelry and loose apparel items E Use insulated tools while working on any electrical components F Set the key switch to OFF and the FWD REV switch to NEUTRAL Use chocks to secure the tires G Components...

Page 23: ...ires Lug nuts should be tightened to 65ft lbs Also check routine and weekly inspection items as listed above Quarterly Inspection by Owner or Technician Driving System Vehicle should operate smoothly during accleration and deceleration Top speed should be limitied to 19mph for non LSV or 25mph for LSV Brake Fluid Brake fluid should be filled and free from contaminates Overall Vehicle Should be no ...

Page 24: ...Reservoir 3 Brake fluid DOT3 Front suspension 4 General purpose lithium base grease Annual lubrication by a Qualified Technician Check the driving axle and fill 37oz Gear lube 5 GL 5 Gear lube Check the front wheel bearing 6 General purpose lithium base grease CHECKING HYDRAULIC BRAKE FLUID LEVELS Never operate your Journeyman if the brake pedal does not feel firm or extends more than halfway to t...

Page 25: ... will limit your top speed when going downhill by transferring some of the excess energy back into the batteries It will also engage to slow the vehicle if it starts to roll away once stopped BATTERY PACK CARE AND MAINTENANCE 1 While charging batteries emit hydrogen which is an explosive gas Keep the vehicle in well ventilated areas while charging 2 Do not smoke or expose sparks or open flames nea...

Page 26: ...for proper care and maintenance It is important to properly condition new batteries New batteries will take numerous charges to reach their full potential During this period it is important not to exceed a 50 discharge level Batteries should be fully charged before first use of vehicle before removal from storage and before use each day Charge batteries whenever possible avoid deep discharging of ...

Page 27: ...le Note a battery watering device or bottle is available at many auto parts dealers 3 Inspect the wires and terminal connections for corrosion fraying or damage Replace wires if necessary Ensure battery wire terminal connector nuts are tightened to 100 in lbs If the battery wires or terminals are damaged or corroded they should be replaced or cleaned Failure to do so may cause them to overheat dur...

Page 28: ...lug While charging use a three pronged wall receptacle with a proper ground Do not attempt to alter the plug in any way Do not use an adapter plug to go from three prongs to a two prong outlet This will result in an ungrounded condition and increase the risk of an electrical shock and or fire If an extension cord is used it must also be a three prong extension cord with 12AWG wires no longer than ...

Page 29: ... m 2 Never connect a charger to the same outlet as any other device Recommended circuits are rated at a minimum of 20 amps CHARGE STATUS the LED light is amber it means in absorption stage FAULT the LED light is red and flashing it means charge error Reset charge power and refer to Troubleshooting below CHARGE COMPLETE the LED light is green it means absorption phase complete or charger in Mainten...

Page 30: ...Flashes Cause Solution Battery high voltage Check battery size and condition and reset charger interrupt AC power for 15 seconds Battery low voltage Check battery size and condition and reset charger interrupt AC power for 15 seconds Charge timeout caused by battery pack not reaching required voltage Charger output was reduced to high temperatures Check connections Operate charger at a lower ambie...

Page 31: ...installed three prong outlet Do not use a two prong adapter Locate all cords and wires in locations that will not be driven over covered or present a tripping hazard Charging the Journeyman Do not use the charger if o The plug is loose or does not make good contact o The plug or wires get hot o The connector pins are bent or corroded o The plug receptacle or connector is damaged in any way Using t...

Page 32: ...ll occasionally check the batteries condition and apply enough power to maintain a full charge It is recommended to plug the charger in even after short trips 10 minutes This will assist in getting the maximum life from your Journeyman batteries CLEANING AND APPEARANCE It is recommended to use automobile car wash soaps and mild household cleaners Use a garden hose with a sponge or towel Do not use...

Page 33: ...Journeyman Operator s Manual Page 28 ...

Page 34: ...transportation and labor are the responsibility of the purchaser unless otherwise stated in this warranty b To qualify for warranty coverage the selling dealer must complete the warranty registration form online within ten 10 days after purchase or lease If this information is not on file with Columbia purchaser must provide proof of date of purchase with any warranty claim c To obtain warranty se...

Page 35: ...lusive sole remedy of the purchaser Columbia makes no other representation or warranty of any kind and no representative employee distributor or dealer of Columbia has the authority of any kind to make or imply representation promise or agreement which in any way varies from the terms of this warranty THERE ARE NO OTHER EXPRESS WARRANTIES ON YOUR VEHICLE BEYOND THOSE SET FORTH HEREIN AND NO IMPLIE...

Page 36: ...Journeyman Operator s Manual ...

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