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SECTION 5 SERVICING YOUR VEHICLE

SU5 OWNERS MANUAL 2014

VEHICLE TROUBLESHOOTING

PROBLEM

CHECK

Will not move

Power keyswitch on.
Direction Selector in desired direction.
Keyswitch for loose wires or faulty switch.
Batteries  for  loose  terminals,  corrosion,  electrolyte  level  or
state of charge.
Motor for loose wires, open circuits or worn brushes.

Will not move with power keyswitch on and the
direction selector is in the desired direction

See Controller Troubleshooting below.

Runs slow

Batteries  for  loose  terminals,  corrosion,  electrolyte  level  or
state of charge.
Brakes dragging

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.

CONTROLLER TROUBLESHOOTING

The AC Drive controller sends fault codes to a Multi-Function Display as seen
in figure 5-1. For codes above operator level, or general assistance with these
codes, consult the service manual or your local authorized dealer.

5-3

Figure 5-1

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Содержание SU5

Страница 1: ...Owner and Operator Manual SU5 P N 712307 CPC P N 99727 14 2014 Find replacement parts for your cart faster at CartPros com ...

Страница 2: ...ion 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 t...

Страница 3: ...IEW DISPLAY PANEL 3 3 WARNING LABEL OPERATING INSTRUCTIONS 3 4 STEERING WHEEL 3 4 CHARGER RECEPTACLE REMOTE LED 3 4 HAZARD WARNING SWITCH 3 5 FUSE BLOCK 12V ELECTRICAL CIRCUIT 3 5 FUSE BLOCK 48V ELECTRICAL CIRCUIT 3 5 WINDSHIELD WIPER WASHER 3 5 TILT BED 3 6 SECOND SEAT 3 6 BATTERY ACCESS 3 6 DRIVING THE VEHICLE 3 6 PRE OPERATION CHECKLIST 3 7 SECTION 4 ELECTRIC SYSTEM IMPORTANT INFORMATION 4 1 BA...

Страница 4: ... TRANSPORTING YOUR VEHICLE 6 1 SECTION 7 VEHICLE STORAGE BATTERY PREPARATION 7 1 VEHICLE PREPARATION 7 2 RETURNING VEHICLE TO SERVICE 7 2 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 d...

Страница 5: ...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 p...

Страница 6: ...e front hood area VIN MATRIX Personal Transport Vehicle PVT Digit 1 thru 3 Abbreviation Model S5S Short S5L Long Digit 4 Power System F Sep Ex Regen ACEplus 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 4 400 Amp B 450 Amp 5 500 amp Digit 8 Brake System V Front Rear Mechanical Digit 9 Build Year N 201...

Страница 7: ...t coupled to oil bath helical geared rear axle Tire PSI 32 psi Rear Axle 16 77 1 helical gear reduction with integral differential Battery Deep Cycle 48 Volt 8 6 volt heavy duty 225 Ah Charger Built in micro processor control fully sealed anti drive away interlock 110 240 V AC 50 60 Hz Speed Control Programmable solid state reduced speed reverse with diagnostic LED and calibrator interface Directi...

Страница 8: ...nimize 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 SAFETY VEHICLE STATEMENTS This vehicle will...

Страница 9: ...acity 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 keyswit...

Страница 10: ... make driving your Columbia vehicle a safe and pleasant experience BATTERY DISCONNECT METHOD Figure 2 1 Batteries are located under the front seats Before performing any vehicle service power down the vehicle using the blue quick disconnect arrow Figure 2 1 2 3 Find replacement parts for your cart faster at CartPros com ...

Страница 11: ...ION 4 ELECTRIC SYSTEM BATTERY INSPECTION MAINTENANCE 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 charger can remain connected to an AC source It has the capability to test and recharge the battery pack during storage INSPECTING THE VEHICLE After battery charging perform an inspection ...

Страница 12: ...ot 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 turned off Turning the keyswitch to OFF is highly recommended whenever vehicle is not in use Always take the key out of the keyswitch when leaving the vehicle DIRECTION SELECTOR Figure 3 2 Selector is located between the se...

Страница 13: ... speed in reverse should always be kept at a minimum MULTI FUNCTION CLEARVIEW DISPLAY PANEL Located on the dash this panel contains the left and rights green turn signal indicators and the AC display This display will show the battery state of charge as a percentage of full charge the system status the operating speed odometer and direction selected Figure 3 5 At power on the display will perform ...

Страница 14: ...gure 3 9 The Vehicle Status selection displays the current state of vehicle data collected at the controller Figure 3 10 WARNINGS OPERATING INSTRUCTION Read this information carefully before operating the vehicle Promptly replace if removed or damaged Contact Columbia ParCar for replacements if needed Part number for the Personal Transportation Vehicles vehicle decal is 53258 07 Figure 3 11 or 439...

Страница 15: ...sher dome etc The fuse block has a snap off cover for access to the fuses FUSE BLOCK 48V ELECTRICAL CIRCUIT Figure 3 14 A fuse block protecting the 48V electrical circuits horn etc of the vehicle is located beneath the rear deck atop the controller assembly The fuse block has a snap off cover for access to the fuses NOTICE If fuses continue to blow and require replacement have your Columbia Dealer...

Страница 16: ...ing the second seat BATTERY ACCESS Batteries are located under the front seats DRIVING THE VEHICLE Complete the following PRE OPERATION CHECKLIST Fasten seat belts if vehicle is so equipped Insert key in power keyswitch press brake pedal firmly and turn key to ON position Switch the direction selector to the direction of desired travel Release the parking brake and brake pedal Slowly press acceler...

Страница 17: ...rosion All terminals and connections are tight Torque connections to 100 in lbs Tire Pressure 32 psi Lights Horn and Reverse Buzzer Head tail and brake lights illuminate Press horn button to sound horn Brakes Brake pedal has firm pedal pressure with minimal travel Parking brake has proper engagement and release Steering Responsiveness and the absence of excessive free play Cargo Load is secure bal...

Страница 18: ...ring the vehicle See SECTION 2 SAFETY BATTERY DISCONNECT METHOD 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 excessivel...

Страница 19: ... with a charger not designed for your vehicle Only trained technicians should service the charger Contact your Columbia Dealer for assistance NOTICE 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 BATTERY INSPECTION MAINTENANCE NOTICE The followi...

Страница 20: ...er cord Wait approximately 30 seconds Reconnect the power cord and allow the charger to complete a second charge cycle If the vehicle is not to be used leave power cord connected The on board charger can test and recharge as needed BATTERY CLEANING Acid soaked debris on the battery terminal connections will cause current leakage reduces battery efficiency and battery life Hose wash battery termina...

Страница 21: ... flashing short green If this LED is not lit check the AC connection and the AC source fuse or breaker If this fails to correct the problem contact your Columbia Dealer for assistance Charger will automatically turn on and conduct a short self test and battery pack test The LED will flash in sequence and then a trickle current will be applied to batteries until a minimum voltage is reached If the ...

Страница 22: ...E If the charger is exhibiting a 3 flash fault and it has been determined that the cause was not due to ventilation or high ambient temperature the following procedure may restore the battery pack to normal operation 1 Battery posts and terminals must be clean and free of corrosion 2 For non sealed batteries check that electrolyte level just covers plates 3 Plug in charger for at least a 16 hour c...

Страница 23: ...To check change the charging algorithm Disconnect the charger positive connector from battery pack Apply AC power and after the LED test the algorithm will be displayed for 11 seconds To change the algorithm touch the positive connector during the 11 second display period to the battery pack s positive terminal for 3 seconds and then remove The algorithm will advance after 3 seconds Repeat until t...

Страница 24: ...ed batteries 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 ...

Страница 25: ...N Remove battery negative cables and then battery positive cables Remove battery hold down Remove batteries from vehicle To install batteries reverse the removal procedure with the negative cables being attached last Torque connections to 100 in lbs SINGLE POINT BATTERY WATERING SYSTEM If equipped NOTICE The following information does NOT apply to sealed batteries This is a single point watering s...

Страница 26: ...e front hood Use DOT 3 Motor Vehicle Brake fluid Maintain fluid level within 1 4 of master cylinder filler opening TIRE CARE See SECTION 1 INTRODUCTION VEHICLE SPECIFICATIONS for recommended tire pressure Improper inflation will shorten the life of your tires and will adversely affect performance NOTICE Replacement tires must be the same size as original equipment Increased tire load ratings are p...

Страница 27: ...rdware bolts nuts Clean body and seats Wash as needed Lube Visually check suspension and differential for leakage MAINTENANCE SCHEDULE QUALIFIED TECHNICIAN It is recommended that the following be performed by a trained qualified technician or your Columbia Dealer Item Operation Quarterly Semi Annual Annual Tires Front wheel alignment Electrical Test batteries Inspect motor condition and operation ...

Страница 28: ... See Controller Troubleshooting below Runs slow Batteries for loose terminals corrosion electrolyte level or state of charge Brakes dragging 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 CONTROLLER TROUBLESHOOTING The AC Drive controller sends fault codes to a Multi Function D...

Страница 29: ...ng precautions T Turn off key O Occupants and or cargo must be unloaded W Walk around vehicle to inspect for any loose or dragging items I Inspect lift mechanism or tow straps chains for secure fit N No parking brake service brake or wheel chocks should be in place G Go no faster than 5 mph while towing vehicle TRANSPORTING THIS VEHICLE NOTICE To transport this vehicle behind an auto or truck on a...

Страница 30: ...or specific gravity of the electrolyte should be checked every 6 to 8 weeks using a voltmeter or hydrometer The batteries should be recharged to a specific gravity of approximately 1 260 sp gr After charging disconnect the batteries See SECTION 2 SAFETY BATTERY DISCONNECT METHOD NOTICE Batteries in a low state of charge will freeze at higher temperatures than fully charged batteries Do not attempt...

Страница 31: ...EHICLE TO SERVICE If necessary connect the battery pack and fully recharge batteries Check tire pressure and readjust if necessary See Section 1 Perform Pre Operational Checklist per Section 3 For vehicles with a single point watering system After the batteries have been fully charged connect the system to its water supply for 3 5 seconds then disconnect regardless of whether or not the batteries ...

Страница 32: ...1115 Commercial Avenue Reedsburg WI 53959 Phone 608 524 8888 Fax 608 524 8380 800 222 4653 Web www parcar com Find replacement parts for your cart faster at CartPros com ...

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