Power Pusher Manual PDF Version
Contents
1. becomes excessive Examination should take place at a minimum of 6 months for the sprocket keyways and monthly for the axle bolts and free wheel hub sliding drive pins this should take place during chain tension and lubrication work specified above Attempt to rotate the drive sprockets observing any movement relative to the spindle Note wear in the hub pin should be obvious during actuation take curative action if wear is detected BATTERIES removal replacement and re chargin BATTERIES SHOULD ONLY BE REPLACED BY A SIMILAR TYPE A Standard fitment is 2x Sonnenschien A512 DRYFIT 60Ah 12V Sealed Valve regulated GelLead Acid CAUTION Each battery weighs approximately 22Kg Use safe lifting practice Removal of batteries will alter the weight distribution of the Power Pusher and will affect its balance Ensure the machine is safely chocked packed 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 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 The Power Pusher is fitted with a GUEST dual output battery charger Mod2. ease manual movement In order to move power pusher manually e without power for other than short distances the drive couplings free wheel hub locks on the wheels can be isolated This is achieved by pulling the spring loaded pins outwards and allowing them to rest in the disconnected position Power Pusher weighs 160Kg without attachments A starting effort of 2 6Kg force is required to move this machine in its basic form Machines fitted with large attachments WILL require more force It must be remembered that more effort is required when pushing up gradients Ensure that assistance is used where necessary Free wheel Hub Lock engaged position shown without optional wheel guards for clarity Asarerr Hub lock must be re instated after manual movement otherwise anti runaway will be ermanently disabled under no circumstances should the machine be allowed to move down falling gradients or be off loaded using ramps with the drives disconnected as an uncontrollable run away may occur DO NOT LEAVE THE MACHINE PARKED WITH DRIVES DISCONNECTED FAULTS In the event of the power indicator not illuminating when the batteries are known to be in a good condition check the battery and controller supply fuses For any other fault condition consult the supplier BATTERY CHARGING Power Pusher is fitted with an EU Compliant GUEST model 2630 230 dual output battery charger intended for 230V AC or GUEST m
3. 38 9 Hoyle Ave Castle Hill NSW 2154 T 61 2 9680 7944 U MS F 61 2 9680 7955 Urethane amp Machinery Supplies sales ums net au POWER PUSHER OPERATION AND SERVICE MANUAL Contents BAPE OP ERATION 5 cdcceseeccscecesouceten seen ct aadecacvearceters TEES 3 COMMISSION IN O dels 3 HAZARD a a tt aar Eo abad 3 MAINTENANCE san dad 3 MAINTENANCE ROUTINE GEC e 4 INSPECTION OF MECHANICAL PARTS siccscacecs sancti cavcctezsaasdevccziessieczcrdcsectcctadecetazeeess id ts ie 4 BATTERIES removal replacement and re charging ccooomoccccnonncnncnnnanccnnnnnancncnnnnnononnn nano nrnnnan nre 4 FUSES it Ii rms am am etu Et ctrca Atte bbc d A Pes 5 CHAIN ADJUSTMEN T liii erea Sd A eb tefesa datu 5 LUBRICATION rore a r ae o e a 5 GLERAPUN S ene eden E E E M DE UD EA T 5 GONTROLES AND OPERATION soli ic de ndus 5 MAIN DG PROVE EY SWITOBIS Larissa dede et apt e ta detach co es oo i Sd dd 5 ROTARY CONTROLS SPEED 8 DIRECTION OF MOVEMENT seen 6 POWER INDICATOR and Low Battery lock out TUNCUON dll 6 ANTI CRUSHING SAFETY FEATURE BELLY SWITCH cooocccccncnonccnonnnonanccnnanannncnnnannnnnnnnnncnnnn en nnne 6 ANTI RUNAWAY FEATURE e cz et illo Teak nates o phe Tue het ecu todo ile 6 FREE WHEEL TIUBS itudin atra ctu AA At ts dads 7 PABEDS raro O PE eun ELA M m y BATTERY CHARGING corae ost isa so eum AM uates xt A Lees O 8 A M does HMM nr 8 CHARGER TROUBLESHOOTING acd stats scene tae oda codes Pe d or Ep Hepat pue
4. e key switch immediately in front of the handlebar assembly controls supply of power to the control electronics This controller supply keyswitch must also be turned to the on position before the machine will function A pemove 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 Power Pusher is controlled by the rotary 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 Power Pusher move forwards away from the operator Reverse rotation towards to operator will make Power Pusher move backwards towards the operator POWER INDICATOR and Low Battery lock out function A 10 LCD CURTIS battery state indicator clock is fitted in the handlebar beam 10 Black LCD s indicate full charge A reduced number of LCD s lit indicate progressive discharge Noie An optionally fitted lock out signal from this indicator to the control processor will prevent machine operation if the batteries are in an excessively discharged state This indicator should illuminate once the two switches are turned on Powe
5. el 2620 230 is intended for connection to a 230V AC supply Model 2620 B is intended for connection to a 110V AC supply FUSES A Fuses must only be replaced by the same type and rating 1 UK 220V mains plug is fitted with a 13A fuse 2 Battery charger output fuses are 15A 3 DC control fuse 1 25 3A Note Battery charger output fuses In line fuses are only fitted in the connections to battery 24V and 12V centre link terminals CHAIN ADJUSTMENT A Disconnect the batteries before commencing Chain adjustment is provided at the motor gearbox slacken the 7 16 inch vertical bolts retaining the motor gearbox and move the assembly until the maximum chain displacement is 1 inch 12 7mm at the centre of the chain run Re tighten the bolts to 8 3 Kg M 60 Ft Lb Chain tension adjustment should be checked every six months 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 CONTR A v ANTI TRAP SWITCH PAD pe 4 4 CONTROLS PICTOGRAM ROTARY E wo A j DIRECTION SPEED adie MN CONTROL WHEEL WARNING HORN SWITCH E gt e Tou CONTROLLER POWER KEYSWITCH MAIN DC POWER SWITCH Controller Power Keyswitch Th
6. ional or larger batteries INSTRUCTIONS FOR ACCESS TO MOTOR AND DRIVE 1 2 nNooR 9 10 11 Open the main body lid 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 22Kg Use safe lifting practices Removal of batteries will alter the weight distribution of the Power Pusher and will affect its balance Ensure the machine is safely chocked packed to avoid tipping if the batteries are to be removed Remove the battery restraint 7 and remove both batteries Note safe handling of batteries Un fasten and remove the charger mounting plate 8 along with the charger Un bolt and remove the battery divider plate 6 Un bolt and remove the battery support plate 5 The Motor gearbox and its mounting frame will now be visible Chain adjustment is provided at the motor gearbox Slacken the 7 16 inch vertical bolts retaining the motor gearbox mounting 24 and move the assembly until the maximum chain displacement is 12 7mm Y inch at the centre of the chain runs Avoid un equal chain tension Re tighten the mounting retaining bolts to 8 3 Kg Metres 60 Ft Pounds 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 a
7. 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 remains ON for more than 48Hrs refer to the troubleshooting section With only the green LED illuminated the battery has reached almost full charge and the charger is delivering top up at less than 3 Amperes The charger circuitry is designed to prevent overcharging CHARGER TROUBLESHOOTING Symptom possible cause __ Solution No mains supply Check supply and mains fuse Charger fault Return charger to Supplier charge Batteries may be defective Replace if necessary Check and tighten Charger output shut down due to overload or Eradicate cause amp replace blown fuses with short circuit same type and rating Charger has shut down due to overheating Wo Mende a cooler environment with Remove mains and then isolate the batteries from the charger Green LED should illuminate when Mains is restored If not the charger may be defective Fuse s blown If fuses and connections are sound return charger to supplier If fuses and connections are sound return Faulty connection charger to supplier 6 Red amp Green LEDs permanently ON 48Hrs Battery damaged or unable to reach full Checkand eses batter charge Poor electrolyte or cell damage p y Return Charger to supplier Change battery Do not attempt to charge addit
8. ited to tyre inspection and pressure checks drive chain tensioning lubrication and battery exchange The machine should be returned to the distributor for any major repairs 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 baiteries if machine is placed in storage e Use protective clothing when handling batteries e Ensure safe practices are employed if changing attachments MAINTENANCE 8 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 anti 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 Certain parts of the drive train are liable to wear in normal use These are a Chain sprocket keyways b Axle freewheel hub bolts c Free wheel hub lock drive pins These items should be examined for wear and replaced if this
9. llow tools to bridge the battery terminals NOTE If the drive chains are badly worn contact the supplier for replacements Drive chains must be replaced as matched pairs pus PARTS LIST REFERRING TO EXPLODED Body Main Power Pusher e ere CTN ACI mowe PmeOmgerMonPuo s orn GwerManPwerPuer O Key Main Axle 14 x 2 12 EIN IE EN ICI NTC CIN IN T D Meme T 11 12
10. m app a Nu Sead tae caido 9 INSTRUCTIONS FOR ACCESS TO MOTOR AND DRIVE ostias 10 PARTS LIST REFERRING TO EXPLODED si nri nur ut inia sitet red ei Ce RR a oc S oett bebe 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 Power Pusher is intended for pedestrian control Riding on the Power 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 Distributor When connecting batteries Please take care to ensure fuses of the correct rating and type must be installed in the battery ve lead It is recommended that the batteries are given an initial overnight charge HAZARDS 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 Please take care to ensure 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 power pusher contains few user serviceable parts Advice servicing is lim
11. odel 2630 B dual output battery charger intended for 110V AC 50 60Hz operation Charging this unit in any manner other than by the charger provided may result in serious damage For the UK market the GUEST model 2620 230 charger is supplied fitted with either a UK 3 pin BS1368A plug which has a 13 Amp fuse installed or the GUEST 2620 B charger is supplied fitted with a yellow industrial 16Amp 2P E PE plug IP44 Replace fuse or damaged plug only with the same type and rating In other countries local electrical regulations apply Batteries supplied with Power 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 The above photograph shows the Guest 2620 230 as installed in the Power 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 Avo NOT ATTEMPT TO MOVE POWER 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 both 12V batteries which are connected in series to supply the Power Pusher These batteries are individually connected to the two charger outputs When the RED LED is illuminated the battery is discharged The charger is recharging at the Bulk charging rate of 10A Voltage
12. r Pusher can be used while black LCD s are shown Note The electronic control unit fitted to Power 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 immediately cause 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 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 ANTI RUNAWAY FEATURE The controller fitted to 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 FREE WHEEL HUBS Power Pusher can be supplied with optional free wheel hubs to
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