SUPER POWER PUSHER OPERATION AND SERVICE MANUAL
Contents
1. Although the batteries supplied with the machine are of a sealed for life type there is a small possibility that acid leakage may occur if the casings have been damaged Use of protective clothing and eye protection is recommended when handling batteries The energy levels that can be delivered by these batteries can cause fire Metal objects must not be allowed to bridge the battery terminals Explosive hydrogen gas may be liberated Do not allow naked lights near to batteries MAINTENANCE The SUPER PUSHER contains few user serviceable parts User servicing is limited to tyre inspection drive chain tensioning lubrication and battery exchange The machine should be returned to the manufacturer for any major repairs A Safety e Do not use this machine in explosive atmospheres e Ensure visibility Use only in well illuminated areas e Keep metal objects away from battery terminals e Remove batteries if machine is placed in storage e Use protective clothing when handling batteries e Ensure safe practices are employed if changing attachments MAINTENANCE amp ROUTINE CHECKS INSPECTION OF MECHANICAL PARTS 1 DAILY The machine should be given a brief visual inspection Any defects noted should be rectified prior to use The handlebar control assembly includes a throttle return spring Freedom of movement and return to centre off position should be established prior to switching the machine on 2 EVERY WEEK The Belly switch an2. a dedicated charging area or room a NO SMOKING sign should be displayed Life expired batteries must be disposed of in an environmentally safe manner If in doubt consult your local authorities regarding safe disposal FUSES A Fuses must only be replaced by the same type and rating 1 UK 220V mains plug is fitted with a 3A fuse 2 Battery charger output fuses are 15A 3 DC control fuse 1 25 3A LUBRICATION The chain should be lubricated once a year more if usage is heavy with SAE30 oil Do not over lubricate CLEANING Avoid excessive penetration of water into the handlebar control assembly and electronics Remove heavy soil with a soap water solution Do not use pressure washers CONTROLS AND OPERATION HANDLEBAR BATTERY INDICATOR GAUGE CONTROLLER POWER KEYSWITCH WARNING HORN BUTTON LOWER ATTACHMENT BUTTON OPTIONAL RAISE ATTACHMENT BUTTON OPTIONAL ROTARY DIRECTION SPEED CONTROL WHEEL BELLY SWITCH MAIN DC POWER SWITCH The Controller Power Key switch immediately in front of the handlebar assembly controls supply of power to the control electronics This controller supply key switch must also be turned to the on position before the machine will function REMOVE THIS KEY IF THE MACHINE IS TO BE LEFT OUT OF SERVICE Turn off while the machine is not being used ROTARY CONTROLS SPEED amp DIRECTION OF MOVEMENT Forward and reverse movement of the SUPER POWER PUSHER is controlled by the ro
3. 2631 Ms SOs Mandra CT 064 The above photograph shows the Guest 2631 as installed in the SUPER PUSHER It is located under the hinged lid of the battery compartment In line 15A fuses are fitted Only use replacements of the same type and rating DO NOT ATTEMPT TO MOVE THE SUPER PUSHER WHILST ON CHARGE USE OF AN EARTH FAULT PROTECTED MAINS SUPPLY IS REQUIRED REPLACE FUSES ONLY WITH THE SAME TYPE AND RATING LED indicators are provided for all three 12V batteries which are connected in series to supply the SUPER PUSHER These batteries are individually connected to the three charger outputs When the RED LED is illuminated the battery is discharged The charger is recharging at the Bulk charging rate of 10A Voltage is between 11 8 and 14 volts When both LED s are illuminated the charger is recharging at an absorption rate between 3 and 6 amperes Voltage will be approximately 14V In either case if the LED s remain ON for more than 48 hours refer to the troubleshooting section The charger circuitry is designed to prevent overcharging CHARGER TROUBLESHOOTING l Symptom possible cause Solution No mains supply Check supply and mains fuse Charger fault Return charger to Supplier 2 LED s illuminate but batteries do not charge fo Batteries may be defective Replace if necessary Check and tighten Charger output shut down due to overload short circuit or Eradicate cause amp replace blown fuses Blown F
4. 38 9 Hoyle Ave Castle Hill NSW 2154 T 61 2 9680 7944 U MLS F 61 2 9680 7955 Urethane amp Machinery Supplies sales ums net au SUPER POWER PUSHER OPERATION AND SERVICE MANUAL Contents AFE fO RRA Bee mt ae ere eR ee en et ne re ee ee Ea ee 3 CII SS ORIN Greased ahahaha te aca ettts ea aae a a aae eea aE AEE ds inda 3 HAZARDS meie da ideas Veer tececet hiten tateed a cadlin cada a tiatharad anode te 3 BVPI INANE esate h tet thet head aod eee Meee ie An Reet ata AIS a NS 3 MAINTENANCE amp ROUTINE CHECKS INSPECTION OF MECHANICAL PARTS seese 3 BATTERIES removal replacement and re CharQing ccceeeeceeeeeeeeeeeeeeeeeeeeeeeeaaeeeeeeeaaeeeeeensaaeeeenenaeeeenens 4 OLST seach acto eect dated A AE EEE dhe TE at TOE E E en Raina E E A hea 4 UN ES PGi ON sesh a e E E A A E O e ttobene Maced al se 4 GEEANING Saera e a a a a a al ek iaiel eat ial Seta 4 CONTROLS AND OP EIA TION xa sce esas deg od ase eecaee icecueaserten sag ad enadsuyaacteexaqseeandey anceecs arxe2 quagdaueseeuedy eoaeaeauees 5 BANS DC POWER SWITO H ar eas Meets See dade a cane sheubectuee a a seas guceae ese conch e ap 5 REMOVE THIS KEY IF THE MACHINE IS TO BE LEFT OUT OF SERVICE cececcceeeeeeecceeeeeseeeeeeens 5 ROTARY CONTROLS SPEED amp DIRECTION OF MOVEMENT ccccceceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeseaeeeeess 5 POWER INDICATOR BDI zaree e a hist al Benes a 8 ali R Si iG 5 ANTI CRUSHING SAFETY FEATURE BELLY SWI
5. TCH vicar catedainshecditeedudiut ddecavtontadaeatitewenentecmhcetes 6 PUT TES UE A LER assess ess bach Shs bao ca cars pach aus ices dees Seat hades tu dah pause Souk Sena ahah tener E sound eoaie anton Sees datas 6 ANT RUNAWAY FEATURE iio ieot e a aee ech Seah det e a dad dic a EE a Aai 6 REAA ANENE EE E E E E E AE ree E EN 6 Tg Ba sneer ne ae ean Oe PERSO a a a ee a nee eee ee 7 CHARGER TROUBLESHOOTING ir cet errearen dist ieie A e E Eaa E e AAE A aE N EE EEan 8 INSTRUCTIONS FOR ACCESS TO MOTOR AND DRIVE ccr taxzedenepcesnpieet bes caye seees sions nawseceederanebpaependtamecaaede 9 REPLACEMENT PARTS renee ee e cee ee atte e a r ta tle tee ty va Ea 9 PARTS LIST REFERRING TO EXPLODED DRAWINGS 00 eccccceseessceeeeeeseeeeeeeeneeeeeeeeeeaeeeeeeaaaeeeeenaaeeeeen 10 EDI WW cai licsn hala E taal ete cata er dis eee ease ete aes Mak caer hi cuted ct aaennaded Samed daients Glee dtaiend ads 11 SAFE OPERATION This machine should only be operated by staff who have been trained in its use and are familiar with the controls attachments and features Super Pusher is intended for pedestrian control Riding on the Super Pusher is not permitted Suitable for use in well illuminated areas only COMMISSIONING Prior to use for the first time the machine should be visually inspected Should any faults be noticed the machine must be returned to the manufacturer It is recommended that the batteries are given an initial overnight charge HAZARDS
6. cket 13 502 009 Drive Chain 14 502 0010 Decal 15 502 0014 PB Switch Bracket Assembly 16 502 117 Handle Assembly 17 502 118 Handle Top Plate Stainless Steel 18 502 119 Handle Bottom Plate Aluminum 19 502 103 Main Body Front Sides 20 502 104 Main Body Frame 21 502 105 Main Top Cover 22 502 106 Battery Tray 23 502 107 Left Chain Guard 24 502 108 Right Chain Guard 25 502 109 Axle Housing 26 502 1010 Axle Shaft 28 502 114 Axle Sprocket Key 1 29 502 115 Axle Sprocket Key 1 12 30 502 125 P7 Tire 31 502 127 Rear Castor Plate 32 500 079 Castor oie
7. ediately cause the SUPER POWER PUSHER to switch to a forward motion and stop when the switch pressure is removed This is to prevent the operator being accidentally crushed by the SUPER POWER PUSHER and the load while reversing Note The machine will stop permanently It will be necessary to turn the power switch OFF and ON again before the machine will function normally if this feature has been activated AUDIBLE ALERT SUPERPOWER PUSHER is fitted with an automotive type electric horn for warning of approach The horn switch is placed at the centre top of the handlebar assembly Press to sound ANTI RUNAWAY FEATURE The controller fitted to the SUPER POWER PUSHER is able to detect movement due to the Back EMF created by the DC motor Should the voltage increase to a certain level the controller will apply an opposite voltage to stop the movement This occurs even when the power switch is OFF or no batteries are fitted BATTERY CHARGING The SUPER PUSHER can be fitted with either a 110VAC or 240VAC input GUEST model 2631 triple output battery charger intended for Charging this unit in any manner other than by the charger provided may result in serious damage Batteries supplied with the SUPER PUSHER are of a heavy duty sealed valve regulated type Life and performance depends upon keeping them charged at all times They should not be stored in a discharged condition CHARGER ENGINE START TROLLING S BATTERY MODEL
8. eries Un fasten and remove the charger 3 Un bolt and remove the battery support plate 22 The motor gearbox 1 will now be visible Chain adjustment is provided at the motor gearbox Slacken the 3 8 inch bolts retaining the motor gearbox and move the assembly until the maximum chain displacement is 2 inch at the centre of the chain runs Avoid un equal chain tension Re tighten the mounting retaining bolts to 62 Ft Lbs Re assemble parts in the reverse order to above ensuring all bolts screws are tightened correctly with all washers re fitted Re fit the batteries ensuring the correct terminal wire relationship Do not all tools to bridge the battery terminals Note If the drive chains are badly worn contact the manufacturer for replacements Drive chains must be replaced as matched pairs REPLACEMENT PARTS Always give the following information when ordering parts 1 2 3 4 Serial Number of the SUPER PUSHER Part Number Part Name Quantity Desired Do not use item numbers when ordering parts always use PART NUMBERS PARTS LIST REFERRING TO EXPLODED DRAWINGS Item No Part No Description 1 502 001 Transaxle 2 502 002 Controller 3 502 003 Battery Charger 4 502 004 Contactor 5 502 007 Battery Indicator 6 300316 MMBB000441 C2 C5 Handset 10 502 005 Axle Bearing 11 502 007 Axle Sprocket 12 502 008 Transmission Spro
9. tary thumbwheels positioned inboard of the handles These are spring loaded to automatically return to the stop position The thumbwheels are connected internally movement of either wheel will initiate movement Machine Speed is dependant on the amount of rotation Rotate the thumbwheel in a forward motion away from the operator to make the SUPER POWER PUSHER move forward away from the operator Reverse rotation towards operator will make the SUPER POWER PUSHER move backwards towards the operator POWER INDICATOR BDI AN LED battery state indicator is fitted in the top handle plate 3 green LED s indicate full charge A reduced number of LED s lit through GREEN to RED indicate progressive discharge This indicator should illuminate once the power is turned on The SUPER POWER PUSHER can be used while yellow indication is shown Note The electronic control unit fitted to the SUPER PUSHER contains a power saving timer If the power switch has been turned on but the machine has not been used for 25 minutes or more the circuit will shut down To use the machine again the key switch must be turned OFF then ON again The key switch should be turned to the off position if machine is in use but with no demand ANTI CRUSHING SAFETY FEATURE BELLY SWITCH A switch pad is fitted in the handlebar assembly facing the operator Should the machine be reversing towards the operator gentle depression of this switch will imm
10. ti trap function must be tested by moving the machine towards the operator and depressing the switch The machine must move away from the operator and stop No movement may then be possible until the machine has been re set Note this test must be performed with good clearance behind the operator 3 PERIODIC The chain sprocket keyways of the drive train are liable to wear in normal use These keys should be examined for wear and replaced if this becomes excessive Examination should take place at a minimum of 6 months for the sprocket keyways This should take place during chain tension and lubrication work Attempt to rotate the drive sprockets observing any movement relative to the spindle The hinged lid of the SUPER PUSHER allows access to batteries and the charger a ee BATTERIES removal replacement and re chargin BATTERIES SHOULD ONLY BE REPLACED BY A SIMILAR TYPE Standard fitment is 3x Sonnenschien A512C 80A A CAUTION Each battery weighs approximately 30Kg Use safe lifting practice Removal of batteries will alter the weight distribution of the SUPER PUSHER and will affect its balance Ensure the machine is safely chocked blocked to avoid tipping if the batteries are to be removed A Lead Acid Batteries must be handled with care Use protective clothing and eye protection when handling batteries A Batteries under charge may liberate EXPLOSIVE HYDROGEN GAS Note If batteries are to be charged in
11. use with same type and rating 3 Charging time excessive in hot weather erty Charger has shut down due to overheating Move machine to a cooler environment with better ventilation Dead short or overload Return Charger to supplier Change Remove mains and then isolate the batteries from the battery Do not attempt to charge charger Green LED should illuminate when Mains is restored additional or larger batteries If not the charger may be defective Fuse s blown If fuses and connections are sound return charger to supplier Faulty connection If fuses and connections are sound return charger to supplier 6 Red amp Green LED s permanently ON 48Hrs aos es es ooo Battery damaged or unable to reach full charge Check and replace battery Poor electrolyte or cell damage Hole FOR ACCESS TO MOTOR AND DRIVE OV a Consult the exploded drawings to identify parts referred to by ITEM number Open the main body lid 21 and secure safely in the open position or remove it Disconnect and remove all cables from the batteries first noting their positions and fuses to ensure correct re assembly CAUTION Each battery weighs approximately 30kgs Use safe lifting practices Removal of the batteries will alter the weight distribution of the SUPER PUSHER and will affect its balance Ensure the machine is safely chocked blocked to avoid tipping if the batteries are to be removed Remove the three batteries Note safe handling of batt
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