ErgoPower Self-Propelled. Utility Truck Revision

Transcription

1 ErgoPower Self-Propelled Utility Truck - 1 -

2 CONTENTS Introduction..3 Feature Guide Controls and Display Batteries and Charging Operation.12 Care and Maintenance Battery Replacement Fuse Replacement Trouble Shooting Technical Contact Information Warranty

3 INTRODUCTION: Congratulations on your purchase of your new Kingsley ErgoPower Self-Propelled Utility Truck. This ErgoPower Self-Propelled Utility Truck system uses our standard 30 or 36 long aluminum flat or angled utility cart with an electronic power system that is quiet with a long-life battery and built-in charging station. With just a pull of a throttle the cart effortlessly transports heavy loads over all types of surfaces, up ramps, and around tight corners. The operating system on the unit is intuitive, easy-to-operate with lockable key switch. The power-assist motor transports packages and equipment up ramps and aisles all without the effort of the operator. The drive train is water resistant to ensure the liability and durability of the unit in all weather conditions such as rain or snow. The ErgoPower Self-Propelled Utility Truck has the load capacity of 300 lbs. This manual contains important information regarding the safe use of the Ergo Power Self-Propelled Utility Truck. Read it carefully before using the ErgoPower Self-Propelled Utility Truck and make sure you understand all the instructions. If you do not understand these instructions (or any part of them) or have any questions, contact a Kingsley Representative at: , or at info@kingsley.com - 3 -

4 FEATURE GUIDE: The ErgoPower Self-Propelled Utility Truck contains three major components: 30 or 36 long aluminum flat or angled utility cart, control panel and drive train. Utility Cart: 30 or 36 long aluminum flat or angled utility truck Control Panel: located along the Back of the utility truck. Drive Train: located under the utility truck. *Charging Socket: Located below control panel under the right side handle on the race way

5 CONTROLS AND DISPLAY Ergo Powered Console The Ergo Powered console houses all of the controls needed to operate your utility truck s, including the speed adjustment dial, key switch, battery condition meter, status LED, horn buttons, and throttle control lever. See figure 01. Comment [ERL1]: Update photo Figure 01. Ergo Powered Console Speed Adjustment Dial This Dial allows you to preselect and limit your cart s top speed. The image of the tortoise represents the slowest speed setting. The image of the hare represents the fastest speed setting. Key Switch Insert the key into the switch and turn it clockwise to power up (turn on) your utility truck. Turn the key counterclockwise to power down (turn off) your utility truck. Warning if the key is turned to the off position while your utility truck is in motion, the electronic brakes will engage and your utility truck will come to an abrupt stop! - 5 -

6 Battery Condition Meter When the key is fully inserted and turned clockwise to power up your utility truck, this meter indicates the approximate battery voltage strength. For further information on battery charging, see pages Batteries and Charging Throttle Control Lever This lever allows you to control the Forward Speed and the reverse speed of your utility truck up to the maximum speed you preset with the speed adjustment dial. To Move Forward: Use your Right hand to pull up right side of the throttle control lever. To Move Rearward: Use you Left hand to pull up the left side of the throttle control lever. Release the Throttle control lever and allow your cart to come to a complete stop before engaging the other side of the lever. When the throttle control lever is completely released, it automatically returns to the center stop position and engages your utility truck s brakes. Off-board Charger Port The off-board charger power cord plugs into this port during battery charging. The offboard charger port is located on the right side of the raceway located under the throttle control lever. See Figure 02. Figure 02. Off-board Charger Port (mounted) - 6 -

7 Electrical System Fuses Your utility truck is equipped with a series of electrical system fuses, which will help protect the off-board charging system and key switch from receiving an overload of electrical current. These fuses are the same type used in automobiles and are located in a compartment on the right side of the raceway under the off-board charger port. See figure 03. See pages Care and Maintenance for fuse replacement pages. Figure 03. ergopower Console Fuses NOTE: Keep all electrical areas clean and free of moisture and foreign material. Status LED The Status LED alerts you to electrical problems that may occur with the cart. The LED remains constantly lit while your cart is on. If your cart develops an electrical problem, the status LED will flash a code. An audible beep will also sound in tandem with the status LED. See pages Basic Trouble shooting for flash codes. Horn Buttons These buttons activate a warning horn. Your utility truck must be powered up for the horn to be operational. DO not hesitate to use the warning horn, when doing so may prevent accident or injury. Main Circuit Breaker (Reset Button) When the Voltage in the Batteries become low or your cart is heavily strained because of excessive loads, the main circuit breaker may trip to protect the motor and electronics from damage. When the breaker trips, the entire electrical system shuts down. See Figure 04 The Reset button pops out when the breaker trips. Allow a minute or so for the electronics to rest. Push in the reset button to reset the breaker, If the breaker trips frequently, you may need to charge the batteries more often or your batteries may need to be replaced. If the main circuit breaker trips repeatedly, contact the authorized service technician (PBR). See page

8 Figure 04. Main Circuit Breaker (Mounted underneath the utility truck on the opposite side of the motor.) Manual Freewheel Lever If your utility truck runs out of power and you need to push it to your designated charging area, you can put it in freewheel mode. See Figure Remove the key from the key switch. 2. Push up on the manual freewheel lever to disable the drive system and the brake. This will enable you to push the utility truck. 3. Pull down on the manual freewheel lever to reengage the drive and the brake systems and take your utility truck out of freewheel mode. Warning! When your utility truck is in freewheels mode, the braking system is engaged. Disengage the drive motor only on a level surface. Ensure the key is removed from the key switch. After you have finished pushing your utility truck, always return it to the drive mode to lock the brakes. Note: if the utility truck is placed in freewheel mode (Manual freewheel lever up) while the key is in the on position, the utility truck will not run until the manual freewheel lever is pulled down and the key is turned to the off position, then back to the on position. Figure 05. Manual Freewheel Lever (mounted) - 8 -

9 BATTERIES AND CHARGING Batteries and charging Your utility truck requires two 12volt, deep cycle batteries that are sealed and maintenance free. They are recharged by an off-board charging system. Charge your utility trucks batteries prior to using it for the first time. Keep the batteries fully charged to keep your cart running smoothly. Figure 06. Battery Voltage Meter Reading your battery voltage The battery voltage meter on the utility truck console indicates the approximate strength of your batteries using a color code. From right to left, green indicates fully charged batteries, yellow indicates a draining charge, and red indicates that an immediate recharge is necessary. See Figure 06. To ensure the highest accuracy, the battery condition meter should be checked while operating your utility truck at full speed on a dry, level surface. Charging your Batteries The ergopower Self Propelled Utility Truck uses two 12V direct current gel batteries. The standard battery charger provided is a 24V 2AMP Battery Charger with VAC input. A charging indication light can be found on the main body of the battery charger. The indication light illuminates RED during charging and GREEN when fully charged. It will normally take 4 to 6 hours to fully charge the batteries depending on environmental conditions. The battery charger has built in safety features and can be left connected indefinitely without harming the batteries

10 An optional 24V 6AMP Constant Current Battery Charger is available for the ergopower Self-Propelled Utility Truck. The optional charger charges faster (normally within 1 hour to fully charge the batteries depending on environmental conditions) and can accept both 115V and 230V inputs. Part number CHR2 For more information regarding the battery charger or to purchase the charger, go to Note: If the Batteries run out of a charge during operation, there is a gear release switch lever on the right hand side of the Transaxle motor assembly located underneath the utility truck that can be pushed up to enable the cart to be pushed to the designated charging area. Do not forget to re-engage the transaxle by pushing down on the lever after the batteries are charged. See Figure 05. For more information regarding the battery charger or to purchase them, please contact Kingsley Company. *Note: the utility truck is not to be operated when the charger is plugged in. Prohibited! Removal of grounding can create an electrical hazard. If necessary, properly install an approved 3 pronged adapter to an electrical outlet having 2 pronged plug access. Prohibited! Never use an extension cord to plug in your battery charger. Plug the charger directly into a properly wired standard electrical outlet. Prohibited! Do not allow unsupervised children to play near the utility truck while the batteries are charging. We recommend that you do not charge the batteries while the utility truck is loaded with material. Mandatory! Read the battery charging instructions in this manual and in the manual supplied with the battery charger before charging the batteries

11 Warning! Explosive gases may be generated while charging the batteries. Keep the utility truck and battery charger away from sources of ignition such as flames or sparks and provide adequate ventilation when charging the batteries. Warning! You must recharge your utility truck s batteries with the supplied off-board charger. Do not use an automotive-type battery charger. Warning! Inspect the battery charger, wiring and connectors for damage before each use. Contact the authorized service technician if damage is found. Warning! Do not attempt to open the battery charger case. If the battery charger does not appear to be working correctly, contact the authorized service technician. Warning! If the battery charger is equipped with cooling slots, then do not attempt to insert objects through these slots. Warning! If your battery charger has not been tested and approved for outdoor use, then do not expose it to adverse or extreme weather conditions. If the battery charger is exposed to adverse or extreme weather conditions, then it must be allowed to adjust to the difference in environmental conditions before use indoor. Refer to the manual supplied with the battery charger for more information

12 OPERATION Before operating your Utility Truck Have you fully charged the batteries? See pages 9-11 Batteries and Chargers Please note that maximum efficiency can only be achieved with sufficient battery power. Is the manual freewheel lever in the drive (down) position? Never leave the manual freewheel lever pushed up unless you are manually pushing your utility truck. Visually inspect your utility truck all around to make sure the unit is under the correct operating conditions. Before operating the utility truck check for any obstructions in the carts path and remove them if needed. (Do not forget to unplug the charger if it is still plugged into the off-board charging port.) Operating your Utility Truck Keep both hands on the utility truck at all times while operating your utility truck. This will ensure that you have full control over your utility truck. Insert Key in key switch and turn on. Set the speed adjustment dial to your desired speed. Push or pull the appropriate side of the throttle control lever The electromechanical disc park brake will automatically disengage and the utility truck accelerate smoothly to the speed you preselected with the speed adjustment dial. Pull the left handgrip to steer your utility truck to the left. Pull on the right handgrip to steer your utility truck to the right. Move the utility truck to the center position to drive straight ahead. You should keep normal driving posture (left and right hand grasping the handle bar grips) at all times when the utility truck is in motion to maintain proper control of your utility truck. Safety The ergopower Utility Truck is intended to help you with Transporting material, offices supplies, equipment, packages, books, and much more inside or outside your building. To ensure safe maneuvering for you and others, please observe the rules listed below: Do not operate the ergopower Self-Propelled Utility truck without reading this instruction manual. Do not use the throttle in an erratic manner when going up or down an incline, maneuvering in tight places, or around a high pedestrian traffic. Do not carry passengers or exceed the maximum load weight of 300Lbs. Do not turn the key switch to ON ( ) position until ready to put the utility truck in motion. Come to a complete stop before changing direction of the utility truck. Come to a complete stop before changing speed dial. Always be aware of what is going on around you while operating the ergopower Self-Propelled utility truck; and Drive Safely

13 CARE AND MAINTENANCE Battery Replacement Tools required for the removal and installation. 2 open end 7/16 wrenches Phillips #2 screwdriver 1 set of pliers Prior to the removal/installation of any part always make sure that the key ignition is in the OFF position, then remove key. Make sure that the charging cord is not plugged into the charging port Step 1. Remove any type of material on the utility truck. Place a mat or a pad next to the utility truck. Once the pad has been placed on floor, carefully turn the cart upside down as shown below. (Requires two people)

14 Step 2. Once the utility truck has been turned upside down you will now be able to gain access to the battery pan. Before battery pan is removed make sure all harness connectors are disconnected from battery box. As shown below Step 3. Locate the (4) bolts that secure the drivetrain frame to the utility truck. Unfasten nuts and bolts and place aside, before removing the entire frame confirm that all harness and wires are disconnected. A (2) person tem lift is required to lift the frame assembly away from the utility truck. Once the frame assembly is clear from the utility truck place the assembly on the ground

15 Step 4. Once the drive train assembly has been removed. Locate the (4) bolts and nuts that secure the battery pan to the frame as shown in image below, unfasten nuts and bolts and place aside. Step 5. Once battery pan has been removed from frame assembly place the battery pan on worktable or bench. Remove battery pan cover and locate batteries to be replaced. Using the pliers and Phillips screwdriver. Remove the connector cables as shown below, please note: be sure to mark the connector s locations prior to removing the batteries that are to be replaced, doing this will ensure proper reinstallation of the battery cables

16 Step 6. Once the batteries have been installed into the battery pan make sure terminal boots are in place as shown in image below. Step 7. Cover the batteries with the battery pan cover then re-install the battery pan assembly onto the drivetrain frame. Secure the (4) bolts and nuts to the frame, then install the drive train frame assembly back on to the utility truck using the (4) bolts and nuts making sure that the bolts and wing nuts are securely fastened. Reinstall the Main cable connection to the battery pan then using a team lift partner tilt the cart upright back on its wheels. Fuse Replacement In the event a fuse should cease to work: 1. Remove the fuse by pulling it out of the slot. 2. Examine the fuse to be sure it is blown. See Figure 07 and Insert a new fuse of the same rating. Warning! The replacement fuse must exactly match the rating of the fuse being replaced. Failure to use properly rated fuses may cause damage to the electrical system. Figure 07 Working Fuse Figure 08 Blown Fuse

17 Storing your Utility Truck If you plan on not using your utility truck for an extended period of time, it is best to: 1. Fully charge its batteries prior to storage 2. Disconnect the batteries from the utility truck 3. Store your utility truck in a warm dry environment. 4. Avoid storing your cart where it will be exposed to temperature extremes. Warning! Always protect batteries from freezing temperatures and never charge a frozen battery. Charging a frozen battery can result in damage to the battery. Batteries that are regularly and deeply discharged, infrequently charged, stored in extreme temperatures, or stored without a full charge may be permanently damaged, causing unreliable performance and limited service life. It is recommended that you charge the utility truck batteries periodically throughout periods of prolonged storage to ensure proper performance. TROUBLESHOOTING What if my utility truck does not move when I engage the throttle control lever? When the manual freewheel lever is pushed up, the brakes are disengaged and all power to the motor/transaxle assembly is cut. Pull down on the manual freewheel lever, turn the utility truck off, and then turn the utility truck on to return to its normal operation. What if the main circuit breaker repeatedly trips? If the main circuit breaker trips repeatedly, contact the authorized service technician. Charge the batteries more frequently. See page 9-11 Batteries and Charging If the problem continues, contact the authorized service technician (PBR). See page 19 You may also perform a load test to determine if the batteries need to be replaced. Battery Load Testers are available at most automotive parts stores. Follow the directions supplied with the load tester. What if the Battery condition meter dips way down and the motor surges or hesitates when I engage the throttle lever? Fully charge your utility truck s batteries. See pages 9-11 Batteries and Charging Contact the authorized service technician (PBR) See Page 19. See the previous troubleshooting question for load testing the batteries yourself. To determine if the batteries need to be replaced

18 If you experience any problems with your utility truck that you are not able to solve, immediately contact the authorized service technician for information, maintenance and service. Any electromechanical device occasionally requires some troubleshooting. However, most of the problems that may arise can usually be solved with a bit of thought and common sense. Many of these problems occur because the batteries are not fully charged or because the batteries are worn down and can no longer hold a charge. Diagnostic Fault Codes The diagnostic fault codes for your utility truck are designed to help you perform basic troubleshooting quickly and easily. The utility cart will either display a diagnostic flash code or emit a beep code in the event one of the conditions listed below develops. NOTE: Your utility cart will not run unless the fault code condition is resolved and the utility cart has been turned off, and then turned back on. FAULT CODE CONDITION SOLUTION (1) Battery charge is low. Charge batteries as soon as possible (2) Battery Charge is too low. Charge Batteries. (3) The cart s battery voltage is too high to operate the utility truck, Unplug charger and/or turnkey off, then back on again. or the charger is still connected to the off-board charger port. (4) Current limit time out. Turn the utility truck off for a few (5) (6) The manual freewheel lever is in the (forward) freewheel position. Throttle control lever not at center position at start up. minutes, then turn it back on. Remove the key from the key switch, then push the manual free-wheel lever to the drive (rearward) position and restart your cart. Return the throttle control lever to center position, turn utility truck off then back on. (7) Speed Pot Error. Call the authorized service technician (PBR). (8) Motor volts error. Call the authorized service technician (PBR). (9) Other internal errors. Call the authorized service technician (PBR). What if all systems on my utility truck seem to be dead? Make certain the key is in the on position. Check that the batteries are fully charged. Push in the main circuit breaker reset button. See page 7 Main Circuit Breaker

19 Disassembly WARNING! Disassembling your utility truck without PBR or Kingsley Companies prior consent can result in the void of your utility truck s Warranty. The ergopower Self-Propelled Utility Truck should not be disassembled without prior instructions from PBR or Kingsley Companies. Please contact PBR if you are experiencing any difficulties with the electronics of your ergopower Self-Propelled Utility Truck. See Technical Contact Information on page 19. Technical Contact Information For Electrical Technical help and troubleshooting information on the ergopower Self- Propelled Utility Truck s: Please contact PBR Scooter Power Chair & Vehicle Lift Repair at: Phone #: Calls will be returned within 24 hours. pchsclf@hotmail.com Additional electrical technical support and service plan can be purchased for $99.00 per additional year or $295 per 4 year period from PBR Scooter Power Chair & Vehicle Lift Repair. All other requests regarding the Utility Truck s that are not electrical related please contact: Kingsley Companies Phone#: or info@kingsley.com CONTACT INFORMATION Kingsley Company 5525 E. Gibralter Street Ontario, CA Tel: info@kingsley.com

20 Kingsley Companies Ergo Powered Warranty Revised August 2014 All of us at Kingsley appreciate our customers and their needs. The below Ergo Powered Warranty is our commitment to provide answers to any Warranty concerns you may have. All Kingsley products go through a vigorous Quality Control procedure at every level of manufacture and again at the point of packaging and shipment. Rest assured in the vast majority of shipments, there will never be a Warranty issue. If one does arise, be assured that every effort will be made to return your Ergo Powered product to working condition in the shortest time possible. Exclusions & Limitations to all Warranties herein: Kingsley uses a Common Sense approach to Warranty Exclusions & Limitations. THIS WARRANTY COVERS ONLY WHAT KINGSLEY HAS MANUFACTURING CONTROL OVER in Design. Manufacture or assembly. The following is outside our control and resulting damages are not covered under any provision within this Warranty Abuse, neglect, or use for other than intended Vandalism Damage from impact/collision, Accident Normal wear & tear Natural disasters like hurricanes, hail, tornadoes, excessive winds, earthquakes, etc. War or acts of terrorism Customer or unapproved Reseller modification of any type voids all Warranties Improper operation, maintenance or storage Failure to adhere to the product instructions Lack or neglect of needed repair or service Exceeding the weight Limit of the unit Wear items: Fuses, Tires, Casters, Springs, felt Padding

21 ALUMINUM PRODUCTS STRUCTURAL & RUST WARRANTY ALL KINGSLEY PRODUCTS WITH A PRIMARY CONSTRUCTION MATERIAL OF ALUMINUM ARE WARRANTIED AGAINST STRUCTUAL FAILURE AND RUST THROUGH FOREVER to the extent of the Limitation and Exclusions, above. The following parts will be repaired or replaced at our discretion, free of charge, for the following allowable time periods from the date of purchase. Lifetime Limited Warranty: Structural frame components, including: cart shell, float tray, and frame welds 1 Year: All electronic parts including controllers, battery chargers, and Wire Harness(es) o Note: while charging batteries, it is normal for the battery charger to heat up. Heat from the battery charger DOES NOT constitute a defect. 1 Year: Drive train differential motor o Note: an increase in operating noise of the motor/gearbox DOES NOT constitute a defect. With normal wear and tear, operating noise is expected to increase. 6 Months: The batteries are covered by a separate six (6) month warranty, provided by the battery manufacturer

22 Electrical Technical Support One year of electrical technical support is included with every Ergo Powered product, supported By PBR Scooter Power Chair and Vehicle Lift Repair. Additional Support can be purchased from PBR at $99.00 per additional year or at $ per 4 year period. (See Technical contact info for PBR information) The following parts are covered by the electrical warranty /support: Wire harness Controller gauges Throttle control lever system Computer Control module All other warranty issues are covered by Kingsley Companies. Consequential & Incidental Damages Notwithstanding anything to the contrary elsewhere in this Agreement or provided for under any applicable Law, no party shall, in any event, be liable to any other Person, either in contract or in tort, for any consequential, incidental, indirect, special or punitive damages of such other Person, including loss of future revenue, income or profits, diminution of value or loss of business reputation or opportunity relating to the breach or alleged breach hereof, whether or not the possibility of such damages has been disclosed to the other party in advance or could have been reasonably foreseen by such other party. END