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Columbia Chariot - User Manual

Columbia Chariot
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Owner’s
and
Operators
Manual
CR-10
Chariot
Electric
Vehicles
PN 709642-03 5/2011
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Summary

Owners and Operators Manual

Preface

Welcome and congratulations on your choice of vehicle, covering design and safety conformance.

Introduction

Safety Messages

Details safety message types (DANGER, WARNING, CAUTION, NOTICE) and their importance.

Vehicle Description

Describes the Chariot as a single passenger, stand-up operation vehicle for smooth surfaces.

Vehicle Identification Number (VIN)

Explains the unique VIN, its features, and its location on the vehicle nameplate.

VIN Matrix

Provides a breakdown of the 13-digit VIN structure used after February 2006.

Vehicle Specifications

Lists key operational specifications including capacity, speed, dimensions, and tire types.

Safety

Getting Started

Operator's responsibility to read, understand, and follow operational and maintenance rules.

Safety Vehicle Statements

Highlights DANGER, WARNING, and CAUTION statements regarding vehicle modifications and operation.

Safety Warnings

Provides critical warnings for personal safety, stability, and control during operation.

Safety Concerns

Outlines operator and owner responsibilities for ensuring safe driving and vehicle condition.

Lifting Instructions

Details precautions and procedures for safely lifting or working on the vehicle.

Battery Disconnect Methods

Instructs to disconnect battery leads before performing any maintenance on the vehicle.

Battery Removal and Installation

Provides the step-by-step procedure for removing and installing vehicle batteries.

Operations and Controls

Inspecting the Vehicle

Guidelines for performing pre-delivery and pre-operation checks for safe working order.

What to Do If You Have a Problem

Advises on reporting delivery damage and handling service issue problems.

Vehicle Controls Overview

Introduces the various controls of the vehicle, identifying their locations and functions.

Keyswitch Operation

Explains how to use the keyswitch to energize the vehicle and select direction.

Battery State of Charge Meter

Describes the analog gauge that indicates the battery's charge level.

Horn Button and Charger Receptacle

Details the horn button location and the charger receptacle for battery charging.

Battery Charging Indicators and Switches

Explains charging status lights and the low battery reset switch.

Warning Labels and Foot Treadle

Emphasizes reading warning labels and describes the foot treadle for acceleration/braking.

Steering Handle Bars

Describes the steering system and provides safety warnings for its use.

Vehicle Operating Instructions

Provides essential guidelines for safe driving, turning, and operating the vehicle.

Parking Procedures

Outlines the correct steps for parking the vehicle safely and securely.

Pre-Operation Checklist

Lists critical items to inspect before operating the vehicle to ensure safety.

Electric System

Important Information on Electric System

Discusses deep cycle battery service requirements and critical safety warnings.

Battery Inspection and Maintenance

Details procedures for checking electrolyte levels, cleaning, and tightening battery connections.

Battery Cleaning

Provides instructions for cleaning battery terminals and connections to prevent leakage.

Conditions Affecting Charging

Explains factors like temperature, age, and discharge state that impact battery charging.

Battery Charging

Covers charger information and the step-by-step operating instructions for charging.

Low Battery Reset Switch

Instructions for using the reset switch when batteries are heavily over-discharged.

Charger Troubleshooting Chart

A chart to help diagnose and resolve common issues with the vehicle charger.

Specific Gravity Test

Describes how to measure battery condition using a hydrometer and specific gravity.

Tips for Prolonging Battery Life

Offers advice on proper charging habits and battery care to extend lifespan.

Vehicle Troubleshooting

Provides a guide for diagnosing and checking common vehicle operational problems.

Servicing Your Vehicle

Maintenance Guidelines

General recommendations for keeping the vehicle in safe and correct operating condition.

Brake System

Details the rear drum brake system and provides instructions for adjustment.

Cleaning Procedures

Instructions for washing the vehicle body, seat, and underside.

Maintenance Schedule - Owner;Operator

Provides a schedule of routine maintenance tasks for owners and operators.

Maintenance Schedule - Qualified Technician

Outlines recommended maintenance tasks for trained technicians or dealers.

Vehicle Storage

Battery Preparation for Storage

Instructions for fully charging and preparing batteries before storing the vehicle.

Vehicle Preparation for Storage

Steps to prepare the vehicle itself, including tire pressure and cleaning.

Returning Vehicle to Service

Procedures for bringing the vehicle back into service after a storage period.

Summary

Owners and Operators Manual

Preface

Welcome and congratulations on your choice of vehicle, covering design and safety conformance.

Introduction

Safety Messages

Details safety message types (DANGER, WARNING, CAUTION, NOTICE) and their importance.

Vehicle Description

Describes the Chariot as a single passenger, stand-up operation vehicle for smooth surfaces.

Vehicle Identification Number (VIN)

Explains the unique VIN, its features, and its location on the vehicle nameplate.

VIN Matrix

Provides a breakdown of the 13-digit VIN structure used after February 2006.

Vehicle Specifications

Lists key operational specifications including capacity, speed, dimensions, and tire types.

Safety

Getting Started

Operator's responsibility to read, understand, and follow operational and maintenance rules.

Safety Vehicle Statements

Highlights DANGER, WARNING, and CAUTION statements regarding vehicle modifications and operation.

Safety Warnings

Provides critical warnings for personal safety, stability, and control during operation.

Safety Concerns

Outlines operator and owner responsibilities for ensuring safe driving and vehicle condition.

Lifting Instructions

Details precautions and procedures for safely lifting or working on the vehicle.

Battery Disconnect Methods

Instructs to disconnect battery leads before performing any maintenance on the vehicle.

Battery Removal and Installation

Provides the step-by-step procedure for removing and installing vehicle batteries.

Operations and Controls

Inspecting the Vehicle

Guidelines for performing pre-delivery and pre-operation checks for safe working order.

What to Do If You Have a Problem

Advises on reporting delivery damage and handling service issue problems.

Vehicle Controls Overview

Introduces the various controls of the vehicle, identifying their locations and functions.

Keyswitch Operation

Explains how to use the keyswitch to energize the vehicle and select direction.

Battery State of Charge Meter

Describes the analog gauge that indicates the battery's charge level.

Horn Button and Charger Receptacle

Details the horn button location and the charger receptacle for battery charging.

Battery Charging Indicators and Switches

Explains charging status lights and the low battery reset switch.

Warning Labels and Foot Treadle

Emphasizes reading warning labels and describes the foot treadle for acceleration/braking.

Steering Handle Bars

Describes the steering system and provides safety warnings for its use.

Vehicle Operating Instructions

Provides essential guidelines for safe driving, turning, and operating the vehicle.

Parking Procedures

Outlines the correct steps for parking the vehicle safely and securely.

Pre-Operation Checklist

Lists critical items to inspect before operating the vehicle to ensure safety.

Electric System

Important Information on Electric System

Discusses deep cycle battery service requirements and critical safety warnings.

Battery Inspection and Maintenance

Details procedures for checking electrolyte levels, cleaning, and tightening battery connections.

Battery Cleaning

Provides instructions for cleaning battery terminals and connections to prevent leakage.

Conditions Affecting Charging

Explains factors like temperature, age, and discharge state that impact battery charging.

Battery Charging

Covers charger information and the step-by-step operating instructions for charging.

Low Battery Reset Switch

Instructions for using the reset switch when batteries are heavily over-discharged.

Charger Troubleshooting Chart

A chart to help diagnose and resolve common issues with the vehicle charger.

Specific Gravity Test

Describes how to measure battery condition using a hydrometer and specific gravity.

Tips for Prolonging Battery Life

Offers advice on proper charging habits and battery care to extend lifespan.

Vehicle Troubleshooting

Provides a guide for diagnosing and checking common vehicle operational problems.

Servicing Your Vehicle

Maintenance Guidelines

General recommendations for keeping the vehicle in safe and correct operating condition.

Brake System

Details the rear drum brake system and provides instructions for adjustment.

Cleaning Procedures

Instructions for washing the vehicle body, seat, and underside.

Maintenance Schedule - Owner;Operator

Provides a schedule of routine maintenance tasks for owners and operators.

Maintenance Schedule - Qualified Technician

Outlines recommended maintenance tasks for trained technicians or dealers.

Vehicle Storage

Battery Preparation for Storage

Instructions for fully charging and preparing batteries before storing the vehicle.

Vehicle Preparation for Storage

Steps to prepare the vehicle itself, including tire pressure and cleaning.

Returning Vehicle to Service

Procedures for bringing the vehicle back into service after a storage period.

Overview

The provided document is an Owner's and Operator's Manual for the CR-10 Chariot Electric Vehicle by Columbia ParCar Corp. This manual, identified by PN 709642-03 and dated 5/2011, outlines the vehicle's operation, maintenance, and safety guidelines.

Function Description

The CR-10 Chariot is a single-passenger electric vehicle designed for stand-up operation. Its primary function is to provide efficient transportation within controlled environments such as industrial plants, nurseries, institutions, motels, mobile home parks, and resorts. It is explicitly stated that the vehicle is not designed for over-the-road use and does not conform to Federal Motor Vehicle Safety Standards or EPA regulations for public streets, roads, or highways. The vehicle is designed to comply with requirements for Type E vehicles as described in O.S.H.A. Standard Section 1910.178 (Powered Industrial Trucks) and applicable portions of the American National Standard for Personnel and Burden Carriers (ANSI B56.8 1993 Part III).

The vehicle's acceleration and braking are controlled by a foot treadle platform. Tilting the treadle forward (weight on toes) engages the accelerator for forward movement, while tilting it backward (weight on heels) applies the brake. A spring-loaded parking brake automatically sets when the operator leaves the vehicle and disengages when the treadle is tilted forward. Steering is managed by handlebars, similar to a bicycle, with the vehicle turning in the same direction as the handlebars.

Important Technical Specifications

The manual provides a "VIN Matrix" and "Vehicle Specifications" section, offering key technical details:

VIN Matrix (Post-February 2006):

  • Digit 1 thru 3 (Abbreviation Model): CR1 (CR-10 Chariot)
  • Digit 4 (Power System): A = Series, Resistor
  • Digit 5 (System Voltage): 1 = 12V
  • Digit 6 (VIN Spacer): - = normal, # = Special Product, 0 = Not Applicable
  • Digit 7 (Controller Amperage): Not specified in the provided matrix, but implied as a variable.
  • Digit 8 (Axle/Brake System): Z = Rear Mechanical
  • Digit 9 (Build Year): H = 2009, J = 2010, K = 2011 (Letters I & O not used)
  • Digit 10 Thru 13 (Build Sequence): 1234 (example)

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; or 4.80x8, Foam Filled, 6 ply, Load Range C

The vehicle uses a 12V electrical system, powered by deep-cycle lead-acid batteries. The built-in charger is custom-made for the CR-10, operating automatically when connected to a 110-120 Volt AC power source. It features charging status lights (RED for charging, GREEN for complete) and a Low Battery Reset Switch for heavily over-discharged batteries.

Usage Features

The CR-10 Chariot emphasizes safe and controlled operation.

  • Keyswitch (Figure 3.3.1 Arrow A): Energizes the vehicle. Rotating right for ON, vertical for OFF. If equipped, rotating left enables reverse (REV). The key can only be removed in the OFF position, securing and disabling the vehicle. Operators are warned not to shift direction while the vehicle is in motion and to keep reverse speed at a minimum.
  • Battery State of Charge Meter (Figure 3.3.1 Arrow B): An analog gauge with a needle and colored background, providing continuous battery charge status. A reading in the right white region indicates fully charged batteries. Movement into the far left red region during acceleration is normal, but if it remains there, recharging is needed to prevent shutdown.
  • Horn Button (Figure 3.3.1 Arrow C): Located on the left inside body panel, activated by lateral pressure from the operator's left leg.
  • Charger Receptacle (Figure 3.3.1 Arrow D): For connecting the supplied AC cord to charge the batteries.
  • Low Battery Reset Switch (Figure 3.3.1 Arrow E): Used when batteries are heavily over-discharged and the charger turns off shortly after connection. Pressing for 10 seconds reactivates the charger.
  • Charging Status Lights (Figure 3.3.1 Arrows F): Indicate battery charging status (RED for charging, GREEN for complete).
  • Foot Treadle Platform (Figure 3.3.2 Arrow A): Controls acceleration (forward tilt) and braking (backward tilt). Also automatically engages/disengages the parking brake.
  • Steering Handle Bars: Designed for bicycle-like steering. Operators are instructed to keep both hands on the handlebars and avoid sharp turns at high speeds.

Pre-Operation Checklist (Section 3.4.3): Before each use, operators must inspect:

  • Batteries: Fully charged, AC cord disconnected, electrolyte level covering plates, secure, free of corrosion, tight terminals.
  • Tire Pressure: Inflated to sidewall specifications.
  • Horn: Sounds when pressed.
  • Treadle: Operates smoothly.
  • Labels: All warning and operation labels in place.
  • Steering: Responsive, no excessive free play.
  • Cargo: Secured to bed platform, balanced, not top-heavy.
  • Obstacles: Path of intended travel is clear.

The manual strongly emphasizes safety, including warnings against modifications, operating under the influence, exceeding capacity, and driving on public roads. It also highlights the importance of trained operators and adherence to OSHA and ANSI standards.

Maintenance Features

The manual provides comprehensive maintenance guidelines for both owners/operators and qualified technicians.

General Maintenance Guidelines (Section 5.1):

  • Only trained personnel should maintain, repair, and inspect the vehicle.
  • Always immobilize the vehicle (keyswitch OFF, key removed) before repairs.
  • Disconnect both main battery pack leads before working on electrical components.
  • Block the chassis with jack stands when working under a raised vehicle.
  • Conduct performance checks in authorized areas.
  • Follow safety procedures from Chapter 2.
  • Avoid fire hazards and have fire protection equipment ready.
  • Do not use flammable fluids for cleaning.
  • Work in a properly ventilated area.
  • Regularly inspect and maintain brakes, steering, speed/directional controls, warning devices, guards, and safety devices.
  • Keep the vehicle clean to minimize fire hazards and facilitate detection of loose/defective parts.

Battery Maintenance (Sections 4.2, 4.3, 4.5, 4.7):

  • Electrolyte Level: Check weekly (or before first use for new batteries). Never allow level to fall below plate tops. Add distilled water to cover plates before charging, then fill to just below cell vents after charging. Do not overfill.
  • Cleaning: Periodically hose wash battery terminals with low-pressure water to remove acid spillage, dirt, and debris. Clean terminals with baking soda solution and a stiff brush, then rinse and dry. Ensure vent caps are tight.
  • Connections: Inspect weekly for breakage, loose connections, and corrosion. Replace damaged parts. Ensure battery hold-downs are properly tightened (not too loose or too tight).
  • Charging: Recharge batteries as soon as they are 20% or more discharged (less than 1.238 specific gravity). Avoid deep discharging (below 80% discharge or 1.098 specific gravity) as it significantly reduces battery life. Opportunity charging is encouraged, but a full charge cycle should be completed at least once a day.
  • Storage: Fully charge batteries before storage. Recharge every 6 months (below 4°C), 2 months (4°C-16°C), or monthly (above 16°C). Check specific gravity every 6-8 weeks.
  • Charger: The built-in charger is automatic, turning off when batteries are fully charged. Disconnect AC plug before operating the vehicle.

Brake System (Section 5.2):

  • Mechanical drum brakes on the rear wheels.
  • Adjustment: Loosen jam nut (Arrow A), turn (lengthen) upper brake linkage (Arrow B), then tighten jam nut.
  • Minimum brake shoe lining thickness: 0.080 inches.

Cleaning (Section 5.3):

  • Wash underside to remove dirt/debris, avoiding high-pressure water on speed switch or battery tops.
  • Wash body and seat with mild detergent; avoid abrasives.
  • NOTICE: Do not use harsh detergents, abrasives, or cleaning solvents containing ammonia, aromatic solvents, or alkaline material on the cab.

Maintenance Schedules (Sections 5.4, 5.5):

  • Owner/Operator Schedule (Weekly, Monthly, Semi-Annual):
    • Tires: Check lug nuts, pressure, wear, damage.
    • Electrical: Check electrolyte level, clean battery terminals, wash cases, check general condition of electrical system (connections, frayed/broken cables).
    • Brakes: Adjust.
    • Body and Frame: Inspect for loose hardware, clean body/seats, wash engine/motor compartment and undercarriage.
    • Lube: Oil movement points (body hinges, brake mechanisms and linkage, leaf spring bushings).
  • Qualified Technician Schedule (Weekly, Monthly, Quarterly, Semi-Annual, Annual):
    • Drive: Check treadle adjustment, motor mounting hardware, drive chain adjustment.
    • Electrical: Test batteries, inspect motor condition and operation.
    • Brakes: Inspect, clean, adjust, replace as needed.
    • Control Speed: Lubricate, check contact bars for wear and spring tension.
    • Lube: Rear wheel bearings (grease or replace), repack front wheel bearings.
    • Steering: Check front wheel bearing adjustment, check fork spindle bearing adjustment.

Vehicle Storage (Section 6.0):

  • Preparation: Fully charge batteries, ensure electrolyte is full, clean batteries and connections. Maintain tire pressure, clean vehicle body/battery compartment/underside. Block wheels.
  • Returning to Service: Connect battery pack (if disconnected), fully recharge, check/readjust tire pressure, perform pre-operation checks.

The manual also includes a "Trouble Shooting Chart" for the charger (Section 4.5.4) and "Vehicle Troubleshooting" (Section 4.8) to help diagnose common issues like the vehicle not moving or running slow, providing checks for keyswitch, batteries, motor, brakes, and tires. It strongly advises contacting a Columbia Dealer for professional service if problems persist.

Columbia Chariot Specifications

General IconGeneral
BrandColumbia
ModelChariot
CategoryElectric Vehicles
LanguageEnglish

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