GLOBAL INDUSTRIAL 800574 2 Seat Warehouse Personnel Carrier User Manual

GLOBAL INDUSTRIAL 800574 2 Seat Warehouse Personnel Carrier User Manual

Personnel Carrier

MANUAL AND CONVENTIONS

• Please read the manual carefully before operating vehicle. Keep this manual with the vehicle at all times.
• This manual serves as a guide for the electric utility vehicle. The manual is subject to change without notice. In case of any discrepancies, consider the actual vehicle as correct and use this manual for reference purposes only. Global Industrial is not liable for errors in this manual or any consequential damage that results from the use of this manual.
• For the most up-to-date version of the manual, please refer to the Global Industrial website.
• Throughout the manual, important safety information will be presented with the following headers. Please pay special attention to this information.

Indicates a hazardous situation that, if not avoided, will result in death or serious injury.

Indicates a hazardous situation that, if not avoided, could result in death or serious injury.

Indicates a hazardous situation that, if not avoided, could result in minor or moderate injury.

Indicates information considered important but not hazard related.

RESPONSIBILITIES

The “owner” refers to individuals or legal entities directly using or entrusting others to use the vehicle, as described in this manual.

The owner is responsible for operator training, maintenance and repairs of the vehicle, and adherence to safety guidelines.

The owner must ensure that all operators thoroughly read and understand the manual.

The owner must provide a copy of the manual with vehicle at all times in cases it is rented, loaned, or transferred to another party.

VEHICLE DESCRIPTION

The warehouse personnel carrier primarily is used to carry personnel. It may be used to tow or transport suitable goods on its cargo deck. To ensure safe operation, it is imperative to adhere to the operating instructions and appropriate use cases. Failure to do so can lead to injuries and/or property damage.
Do not overload the vehicle. Never exceed the rated capacity as specified on the vehicle nameplate.

Do not use vehicle in areas with fire and explosion hazards, or in locations that may subject it to corrosion, rust, or dust.

This vehicle is designed and manufactured to conform to ISO3691:1980. Vehicle is not Federal or State DOTapproved and is not equipped to be operated on public roads, streets, or highways. Vehicle is only limited to indoor use with a hard and flat ground. Operation in inflammable, explosive, or corrosive environments can lead to severe bodily injury and/or property damage. Untrained or unauthorised personnel should never attempt to operate or perform maintenance on this vehicle.

Personnel Carrier

GENERAL SAFETY INFORMATION

Safety Warning Labels
WARNING
FAILURE TO COMPLY TO THESE WARNINGS MAY RESULT IN PERSONAL OR FATAL INJURY TO YOU OR OTHERS AND MAY ALSO RESULT IN EQUIPMENT AND-OR PROPERTY DAMAGES.

BEFORE OPERATING VEHICLE:
READ AND UNDERSTAND OPERATOR’S MANUAL (LOCATED EITHER UNDER SEAT OR TOOL COMPARTMENT).
ALL OCCUPANTS MUST BE SEATED IN FACTORY APPROVED SEATS.
DO NOT OPERATE VEHICLE UNTIL ALL OCCUPANTS ARE PROPERLY SEAT WITH THEIR BACKS AGAINST THE SEAT AND FEET FLAT ON THE FLOOR.
DO NOT OPERATE VEHICLE UNDER THE INFLUENCE OF ALCOHOL OR DRUGS.-

WHILE OPERATING VEHICLE:
KEEP BODY INSIDE VEHICLE. ALWAYS REMAIN SEATED IN A MOVING VEHICLE. PASSENGER MUST BE SEATED AND USE HAND HOLDS PROVIDED.
SUDDEN SHARP TURNS, UNBALANCED OR TOP HEAVY LOADS CAN CAUSE VEHICLE TO BECOME UNSTABLE.

OPERATING VEHICLE
TURN KEY TO “ON” POSITION, SELECT FORWARD OR REVERSE, RELEASE THE HAND- OPERATED PARKING BRAKE, AND SLOWLY PRESS ACCELERATOR PEDAL. ALWAYS BRING VEHICLE TO A COMPLETE STOP BEFORE SHIFTING THE DIRECTION SELECTOR

BEFORE LEAVING VEHICLE:
SET DIRECTION SELECTOR TO CENTRE NEUTRAL POSITION.
TURN KEY TO VERTICAL “OFF” POSITION AND REMOVE.
ENGAGE HAND-OPERATED PARKING BRAKE
IF MALFUNCTION OCCURS, OR ADJUSTMENT IS NEEDED, DO NOT USE, HAVE ALL WORK PERFORMED BY AUTHORISED PERSONNEL.

Operating Instructions Label

WARNING
Failure to follow this warning can cause severe personal injury or death.
This vehicle is designed and contructed for OFF-ROAD USE ONLY.
Do not use this vehicle on any public roadway where automobiles or other motor vehicles are present. Such use can be hazardous to the operator and other drivers, passengers or bystanders.

Off-Road Use Only Label

WARNING
Do not operate vehicle without proper training.

Proper Training Label

WARNING
Pinch Point
Keep hands and fingers clear.

Pinch Point Warning Label

Please read the manual carefully before operating vehicle. Ensure the vehicle is in a safe working condition upon delivery and conduct regular inspections thereafter.

If any problems are found, do not operate vehicle until repairs are made. Failure to make necessary repairs could result in fire, severe personal injury, property damage or death.

This vehicle is not Federal or State DOT-approved and is not equipped to be operated on public roads, streets, or highways. This vehicle is only limited to indoor use with a hard and flat ground. Operation in inflammable, explosive, or corrosive environments can lead to severe bodily injury and/or property damage.

Do not drive vehicle unless you are a qualified and trained operator and familiar with the vehicle operational controls.

Any unauthorised repairs, modifications, or adjustments could lead to unsafe conditions resulting in severe bodily injury and/or property damage. Any modifications must be approved by the manufacturer. Global Industrial is not responsible for any consequences resulting from unauthorized repairs, modifications, and adjustments.

Do not operate vehicle under the influence of alcohol or drugs.

Keep all body parts (head, arms, legs) inside this vehicle while vehicle is in motion.

Wear closed toe low heel shoes when operating the vehicle. Avoid wearing any loose clothing that can get caught.

Both operator and passenger must remain seated (one person per seat) while vehicle is in motion.

Operator must confirm that passenger is physically able to secure themselves by holding onto hand holds while being transported in this vehicle

No passengers are allowed to be transported in the cargo deck of the vehicle.

Do not transport passengers while towing.

Do not park vehicle on incline/slope.

Do not overload the vehicle. Never exceed the rated capacity as specified on the Vehicle Nameplate.

Drive slowly when making a turn, especially on wet or inclined surfaces.

Drive slowly up and down grades. Do not drive on steep hills or inclines.

Do not use accelerator to hold vehicle on an inclined surface.

Avoid fire hazards and have fire protection equipment present in the work area Turn the vehicle off and engage parking brake before loading and unloading.

RECEIVING AND UNPACKING VEHICLE

Please read the manual carefully before operating vehicle. Ensure the vehicle is in a safe working condition upon delivery and conduct regular inspections thereafter.

Battery needs to be connected before driving vehicle off its pallet as shown below.

Vehicle is preset to “Slow” setting prior to shipping.
To access speed switch in battery compartment, remove rubber pad on the cargo deck and set aside. With assistance, lift cargo deck off the vehicle. Take precaution on pinch points. Refer to “VEHICLE CONTROLS” part of the manual to learn more about vehicle controls before operating vehicle.

Refer to QR code or link for model no. 800574 unpacking video and instructions:
https://www.globalindustrial.com/p/2-seat-warehouse-personnel-carrier-24v

Inspect the vehicle immediately after delivery and unpacking. If any damage should occur to the packaging, make note of it.

After unpacking the vehicle, ensure to charge it for approximately 10-12 hours before operating.

Examine the contents of all packages and accessories that may have come in separate packages along with the vehicle and ensure everything listed on the packing slip is there. Model no. 800574 includes an on-board charging cable.

Refer to “Before Operating Vehicle” section of this manual to check that the vehicle is in correct operating condition.

VEHICLE QUICK SETUP

Inspect the vehicle immediately after delivery and unpacking. Use the following guidelines to help identify any obvious problems:

• Examine vehicle body for any damage.
• Inspect tires for any wear or damage. Ensure wheel lugs are secure.
• Check that all wire connections, battery cables, and other electrical connections are secure.
• Examine the contents of all packages and accessories that may have come in separate packages with this vehicle. This vehicle is packed with an on-board charger.
• Refer to “Before Operating Vehicle” section of this manual for “Daily Pre-Operation Checklist” to ensure all vehicle functions are working properly
• Fully charge the vehicle upon receipt. The charge time of the new batteries is approximately 10-12 hours.

VEHICLE SPECIFICATIONS

(with strobe light)
Cargo Deck Dimensions| 15.7″x27.5″
Weight| 1397 lbs
Certification| cTUVus-listed charger

Data Name Plate
Do not remove any name plate, warnings, or instructions affixed to your Global Industrial vehicle. Promptly replace any that become damaged or removed.
Each vehicle is assigned with a unique serial number. The serial number can be found on the name plate located below the right side of the driver’s seat.

VEHICLE CONTROLS

1. Steering tiller controls the path of the vehicle and operates similarly to a conventional automobile steering wheel as shown below. To turn the vehicle left, push the tiller away towards the right, i.e., in a counterclockwise direction. To turn the vehicle right, push the tiller away towards the left, i.e., in a clockwise direction

2. Parking brake lever Pushing the lever to “down” position engages the parking brake. Pushing the lever to “up” position disengages the parking brake. Always apply parking brake before stepping away from the vehicle.

3. Emergency stop button is used for cuts off power supply to the vehicle in the case of emergencies. It should be used when vehicle starts to act in an unexpected manner, if there is an odor, or a perceived hazard. To reset it once hazards are removed or corrected, pull and rotate the button. Do not use the switch outside of an emergency or when only parking the vehicle.
   Reset emergency stop button only when hazard has been cleared, and it is safe to operate the vehicle.
   The emergency stop button is to be reserved to be used in case of emergencies ONLY.
   Do not use emergency stop button like a parking brake. Doing so can cause damage or malfunction to the vehicle.

4. Headlight rocker switch turns the headlight (1) on or off. In the ‘up’ position headlight turns on. In the
   ‘down’ position headlight turns off.

5. Key switch is used to power the vehicle on or off. Turn key to “OFF” to turn off vehicle and remove key.
   Turn key to “ON” to turn on vehicle.

6. Forward/neutral/reverse switch Use this switch to select the direction of travel. Operator must release
   the accelerator pedal before selecting a direction. In the “up” position, the vehicle direction is set to forward. In the “down” position, the vehicle direction is set to reverse.
   Return the FNR switch to its centre neutral position when vehicle is not in use.
   Confirm that the FNR is set to the desired direction of travel before pressing the accelerator pedal.
   The reverse alarm will immediately sound when the reverse direction is selected.
   

7. Battery indicator
   The top portion of this instrument is a battery capacity indicator. The bottom portion is an hour meter
   The battery capacity indicator has 10 bars of LED lights (5 green bars, 3 yellow bars, and 2 red bars) indicating the battery’s state of charge. When the second from the right light flashes, 30% of battery capacity remains and vehicle is in energy reserve. When both red lights flash, 20% battery capacity remains, and it indicates that vehicle should be charged immediately.

8. Hour meter The hour meter displays total hours vehicle has been in operation. Time accrues as soon as the vehicle is on.
   It records up to 99999.9 hours. After 99999.9 hours is reached, it resets to 0 hours.

9. USB port 5V/2.1A USB port for charging devices

10. Phone pocket – Convenience feature for operator to stow phone
    

11. Horn – Pressing the horn button located at the left side of the operator’s foot sounds the horn

12. Brake pedal – To stop the vehicle, release the accelerator pedal and depress the brake pedal.
    Upon releasing the accelerator pedal, the vehicle will begin to decelerate.
    Never rest your foot on brake pedal while operating the vehicle. This wears brake pads, creates drag and causes excess battery discharge.

13. Accelerator pedal Pressing accelerator pedal moves the vehicle forward or backward depending on the
    direction selected on the direction selection switch (8). The speed of the vehicle corresponds to the pressure applied to the accelerator.
    The speed and acceleration of the vehicle is governed by the speed selection on the 2-speed switch.

14. Headlight is designed to illuminate the vehicle’s pathway. It is activated with the headlight rocker switch

15. Blue safety light The vehicle is equipped with a blue safety light that turns on when key switch (7) is
    turned to the “ON” position.

16. Strobe light The vehicle is equipped with a strobe light that turns on when key switch (7) is turned to
    the “ON” position, providing additional vehicle visibility.

17. Brake and reverse light At the rear of the vehicle there is a combination rear and brake light. When the brake pedal is depressed, the red LED light illuminates. When the vehicle direction is set to reverse, the center white LED lights turn on.

18. Seat The seat is equipped with an operator presence switch located underneath it. The driver must remain seated at all times while operating the vehicle. If the operator leaves their seat, the power to the vehicle will be disabled.
    The backrest of the seat can be converted to a seat for a rear-facing passenger.
    To convert the backrest to this configuration, pull the lever on the left-hand of the seat while using your other hand to support and push the seat backrest rearward.
    Never carry passenger unless backrest/seat is in “down” position.
    Always verify that passenger is seated and gripping hand hold bars before moving vehicle.
    Never transport more than one operator and one passenger.

19. Speed switch , located in battery compartment, provides the option for operator to select “Normal” or “Slow” mode.
    Vehicle is preset to “Slow” setting prior to shipping.
    To access speed switch in battery compartment, seat backrest will first need to be placed all the way down. Pull the lever on the left-hand of the seat while using your other hand to support and push the seat backrest rearward. Pull on compartment latch and lift the seat up. Take precaution on pinch points.
    

20. On-board charging port – Charge port

21. Tow hitch mounting plate – Mounting point for tow hitch
    Tow hitch is sold separately

VEHICLE OPERATION

If any problems are found, do not operate vehicle until repairs are made. Failure to make necessary repairs could result in fire, severe personal injury, property damage or death.

This vehicle is not Federal or State DOT-approved and is not equipped to be operated on public roads, streets, or highways. This vehicle is only limited to indoor use with a hard and flat ground. Operation in inflammable, explosive, or corrosive environments can lead to severe bodily injury and/or property damage.

Vehicle is only limited to indoor use with a hard and flat ground.

Do not drive vehicle unless you are a qualified and trained operator and familiar with the vehicle operational controls.
Any unauthorised repairs, modifications, or adjustments could lead to unsafe conditions resulting in severe bodily injury and/or property damage. Any modifications must be approved by the manufacturer. Global Industrial is not responsible for any consequences resulting from unauthorised repairs, modifications, and adjustments.

Do not operate vehicle under the influence of alcohol or drugs.

Keep all body parts (head, arms, legs) inside this vehicle while vehicle is in motion to prevent serious personal injury.

Wear closed toe low heel shoes when operating the vehicle. Avoid wearing any loose clothing that can get caught.

Operator must remain on vehicle while it is in motion.

Operating the vehicle while occupants are not fully seated can cause serious personal injury or death. Start/drive vehicle only when all occupants are fully seated and holding onto available hand holds.

No passengers are allowed to be transported in the cargo deck of the vehicle.

Do not overload the vehicle. Never exceed the rated capacity as specified on the vehicle name plate located below the steering wheel.

Do not allow more passengers than the vehicle is designated for.

Drive slowly when making a turn, especially on wet or inclined surfaces.

Drive slowly up and down grades. Do not drive on steep hills or inclines.

Do not drive on grades that exceed the vehicle’s gradeability.

Do not park vehicle on incline/slope.

Do not use accelerator to hold vehicle on an inclined surface.

Operation in inflammable, explosive, or corrosive environments can lead to severe bodily injury and/or property damage.

Turn the vehicle off and engage parking brake before loading and unloading.

Untrained or unauthorised personnel should never attempt to operate or perform maintenance on this vehicle.

Before Operating Vehicle
If any of the following items malfunction or do not work as expected, do not operate vehicle until problem has been correct.

Daily Pre-Operation Checklist

strobe lights turn on when key switch is in “ON” position.
11| Headlight turns on when headlight rocker switch is set to ‘up’ position.
Horn| 12| Horn sounds when horn pedal is pressed.
Accelerator pedal| 13| Operates smoothly. Accelerates when pressure applied.
Brake pedal| 14| Brake pedal has firm pressure with minimal travel.
15| Brake light illuminates when brake pedal is depressed.
Parking brake| 16| Parking brake lever engages and disengages properly.
Steering| 17| Responsive and absent of excessive free play
FNR switch| 18| Vehicle responds to and travels in respective direction settings
Reverse warning sound and reverse light| 19| Reverse warning alarm sounds and reverse light illuminates when vehicle direction selection rocker switch is set to the reverse direction.
Emergency stop| 20| Vehicle power is cutoff when emergency stop is pressed.
Operator presence switch| 21| Vehicle not operable unless driver is seated in seat.

Operating Vehicle

1. Sit on seat. If applicable, ensure rear passenger is seated and holding onto handholds.

2. Insert key, press on brake pedal firmly, and turn key to “ON” position.

3. Switch the FNR switch to the desired direction of travel.

4. Put parking brake in “OFF” position and release the service brake pedal.

5. Slowly press accelerator pedal to reach desired vehicle speed.
   Vehicle is equipped with a speed switch that offers ability to limit the speed of the vehicle to 5 mph.

6. Move the steering tiller in desired direction. To turn the vehicle left, push the tiller away towards the right, i.e., in a counterclockwise direction. To turn the vehicle right, push the tiller away towards the left, i.e., in a clockwise direction.

7. To slow or stop vehicle, release the accelerator pedal and press the brake pedal

After Operating Vehicle

Never park the vehicle on incline.

1. Turn steering wheel to the middle position
2. Allow or bring vehicle to a full stop.
3. Set FNR switch to neutral centre position.
4. Turn key to “OFF” position and remove.
5. Place hand brake in “HAND BRAKE ON” position
6. If needed, charge vehicle.

BATTERIES AND CHARGING

Charging the Vehicle
The Global Industrial personnel carrier contains four, 6V deep cycle gel AGM batteries, which are virtually maintenance-free.
It is recommended to fully charge the vehicle upon receipt. The charge time of the new batteries is approximately 10-12 hours.

Opportunity charging is not recommended

On-Board Charging
Batteries produce explosive hydrogen gas at all times, especially, during charging and discharging. Charge battery in well-ventilated area and avoid areas with open flames, sparks, or other sources of combustion

Do not operate vehicle while charging the batteries.

This vehicle is equipped with on-board charging. The on-board charger port is located on the left side of the vehicle as shown above.

The charger turns itself on when it is plugged into the wall outlet and turns off when the batteries are fully charged.

Extension cords must be 3-wire cord no longer than 2m (6.5’) at 16AWG.

To charge with the on-board charger:

1. Turn off vehicle. (Key switch is turned to ‘OFF’ position and keys are removed.)
2. Connect the cord to the on-board charging receptacle located on the left side of the vehicle.
3. Connect the cord to power source.
4. Once connected, the indicator lights on the charger should initially flash red then flash green to indicate that charging is in progress.

Charging Indication Lights

The charging indication lights are located directly above the on-board charging port.

Battery Maintenance

Always power off vehicle by removing key and disconnecting batteries before servicing or repairing vehicle.

Do not operate vehicle while charging the batteries.

Use electrically insulated tools when servicing batteries to prevent electrical shock.

Disconnect main battery connection before troubleshooting or performing any maintenance on batteries.

Batteries and battery terminals should be kept clean and free of dirt, debris, or corrosion. Use a clean dry cloth to wipe any dust.

CHARGER TROUBLESHOOTING

Charger Error Codes

is reversed.The battery voltage is too low.
Red, green, red, 3s pause| Overvoltage/overcurrent| Restart vehicle and if error light sustains, contact support.
Red, green, red, green, 2s pause| Ambient temperature is too high or too low| Check whether if ambient temperature is too high or if ventilation is good.Check the position of battery temperature sensor.
Green, red, 4s pause| Charger overheating| Check whether if ambient temperature is too high or if ventilation is good.
Red, green, 4s pause| Output undervoltage| Contact support.
Red, green, red, green, red, 1s pause| Input AC anomaly| Check the input voltage and whether the plug has good contact.
Green, red, green, 4s pause| Integrated fault| Restart vehicle and match fault with above faults.

LIFTING THE VEHICLE

Vehicle may be lifted in the highlighted areas using forks or jacks

MAINTENANCE AND REPAIR

The following maintenance procedures are based on cases where the warehouse personnel carrier is used 8 hours a day or 200 hours per month.

Always power off vehicle by removing key and disconnecting batteries before servicing or repairing vehicle.
Untrained or unauthorised personnel should never attempt to operate or perform maintenance on this vehicle.
Always wear suitable personal protective equipment while performing maintenance.
Avoid inflammable areas and any fire hazards.
Work in a clean and properly ventilated area.
Ensure there is safe clearance in the work area.
Ensure area is properly equipped with fire-extinguishing equipment.

Maintenance Schedule

All kinds of deleted hydraulic oil, gear oil, and grease pollute the environment.
Please responsibly dispose of oils according to local regulations.

Item| No.| Check content| Weekly| Monthly| Semi- Annually| Annually
---|---|---|---|---|---|---
Body and chassis| 1| No loose hardware| •| •| |
2| Body and seat are cleanand free of damage.| •| •| |
Fuse| 3| Check that fuse is still functional| | •| |
Battery| 4| No frayed or broken cables| | •| |
5| All terminals and connections are secure| | •| |
6| Burnish any coarse surfaces on the batterycontacts with sandpaper| | | •|
Controller| 7| Contractor functionsproperly| | •| |
Motor| 8| Inspect the wear on carbon brush andselenium rectifier.| | | •|
Reduction gear box (P/N 20502000015)| 9| Replace the gear oil Recommended oil : Hyperbolic gear oil 85W-90 (GL-5)| | | •|
Wheels/tires| 10| Tires are free of damage| •| | |
11| No loose hardware| •| | |
12| Check wear on tires and bearings. Replace if necessary| | | •|
13| Replace tires| | | | •
14| Replace wheel bearing| | | | •
Brake system| 15| Brake pedal has firm pressure with minimal travel.| •| | |
16| Check brake clearance| | | |
17| Ensure that the brace wire is securely fastened| | •| |
18| Clean debris and check wear on friction plates| | | •|
19| Clean, adjust, and replace brakes as needed.| | | | •
Steering| 20| Check that steering is functional and firmly attached| | •| |
Drive axle| 21| Replace sealing element| | | | •

Troubleshooting the Vehicle

the AGM batteries.
| The battery terminals are loose.| Tighten the terminal screws.
| The fuse has been blown out.| Replace the fuse. (part no. 20416000004)
| The accelerator is damaged.| Replace the accelerator. (part no. 35501000020)
Steering feels heavy or ineffective.| The steering is obstructed by debris or a foreign object.| Remove any debris or foreign objects and lubricate with grease. Recommended grease : Lithium grease EP 3
Brake does not work.| The brake friction discs are worn or has oil sticking to it.| Replace LH brake (part no. 30502000002) and RH brake (part no. 30502000002)

Vehicle Controls Wire Diagram

Troubleshooting with Controller LED Indicators

LED display code example 2.4: ☼☼ ☼☼☼☼ means that LED first blinks twice, then turns off, then blinks another four times.

1. Vehicle operation fault creates high current spikes
2. The current sensor is out of range.
3. Controller fault.

| Restart vehicle by turning key switch to ‘OFF’ then ‘ON’ position. If the problem is still here, please change the controller.
1.2| HW FAIL SAFE(Hardware security fault)|

1. Environmental interference is too high.
2. Self-inspection or the watchdog has some problems.
3. Controller fault.

| Restart vehicle by turning key switch to ‘OFF’ then ‘ON’ position. If the problem is still here, please change the controller.
1.3| M- Shorted Short circuit from M- to B-.|

1. There is inside or outside circuit between M- to B-.
2. There are some errors in motor wiring.
3. Controller fault.

| Check the wiring: re unlock the key. If the problem is still here, please change the controller.
1.4| SRO Operation sequence fault when starting the vehicle (SRO)|

1. Operation sequence fault in interlock switch, direction, and key switch.
2. There is circuit broken in interlock switch or direction.
3. The delayed time of operation sequence set before is too short.
4. Operation sequence has a fault or the choice of accelerator has a fault when starting the vehicle.
5. Accelerator adjustment fault

| Check the operation sequence. Check the accelerator adjustment and the code parameter.
2.1| THROTTLE WIPER Hi The accelerator slip end input is too high.|

1. The circuit is broken or short circuit when the accelerator input B+.
2. Accelerator fault.

| Calibrate the input of the slide end of the accelerator, and make it from high input to normal input.
2.2| EMR REV WIRING Emergency reverse lines or the inspection lines are broken circuit| Emergency reverse lines or the inspection lines are broken circuit.| Check the emergency reverse lines or unlock the interlock switch.
2.3| HPD The signal is more than 20% when the vehicle is started and the controller auto- protection function has a fault.|

1. Operation sequence fault in interlock switch, direction, and key switch.
2. Accelerator fault
3. The delayed time of operation sequence set before is too short.
4. There are some errors related to choosing the accelerator type.

| Check the operation sequence, the accelerator adjustment and the code parameter.
---|---|---|---
SRVC TOTAL| Total maintenance timer time is up.| Reset the usageprogrammer.
SRVC TRAC| Traction maintenance timer time is up.| Reset the usageprogrammer.
TOTAL DISABLED| General disable timer time is up| Reset the usageprogrammer.
TRAC DISABLED| Traction disable timer time is up| Reset the usageprogrammer.
2.4| THROTTLE WIPER LO The slide side of the accelerator is too low.|

1. There is broken circuit or short circuit between accelerator and B-.
2. Accelerator fault.
3. Accelerator type choosing fault.

| Calibrate the input of the slide end of the accelerator and make it from high input to normal input.
3.1| FIELD SHORT The coil of the main contractor short circuited.|

1. The coil of the main contractor has been short circuited.
2. The field coil short circuited between B+ to B-.
3. The field coil resistance is too low.

| Check the connector coil and field coil and restart vehicle by turning key switch to ‘OFF’ then ‘ON’position.
3.2| MAIN CONT WELDED The main connector contact adhesion|

1. The main connector is experiencing contractor contact adhesion.
2. The coil driving of the contaminator is short circuit.

| Check the connector and the wiring and unlock the key switch.
3.3| FIELD OPEN The connection of the field winding is open circuit.|

1. The connection of the field winding is an open circuit
2. The field winding is an open circuit.

| Check the connector and unlock the key switch.
3.4| MISSING CONTRACTOR The main contractor is not installed.|

1. The main contractor coil is an open circuit.
2. The main contractor has not been installed.
3. The wire connecting with the main contractor has an open circuit.

| Check the wire and unlock the key switch.
4.1| LOW BATTERY VOLTAGE The battery voltage is low.|

1. The battery voltage is lower than the controller’s minimum working voltage.
2. The battery terminal is corroded.
3. The wire terminal of the battery or the controller is loose.
4. The controller is broken.

| Make the battery voltage higher than the minimal working voltage.
4.2| OVER VOLTAGE The battery voltage is too high.|

1. The battery voltage is higher than the maximum work voltage of the controller.
2. The charger is still connected to the vehicle.

| Make the battery voltage lower than the cut-off work voltage of the controller.
---|---|---|---
4.3| THERMAL CUTBACK Thermal temperature is cut back.|

1. The temperature is more than 85°C or less than -25°C.
2. The vehicle is overloaded.
3. The controller installation is faulty.

| Return the vehicle to normal operational temperatures.
4.4| ANTI-TIE DOWN Mode switch 1 is closed when started.|

1. Mode switch is short circuited with B+.
2. The mode switch is limited in mode 4 or mode 2.

| Reset up mode 1
MOTOR HOT The motor is overheated.| Excitation resistance is higher than the set resistance when the motor is overheated.| Lower the excitation resistance than the set resistance when the motor is overheated.
MOTOR WARM The motor is over hot.| Excitation resistance is higher than the set resistance when the motor is overheated.| Lower the excitation resistance than the set resistance when the motor is overheated.

STORING THE VEHICLE

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