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Owners manual MELEX 4XX
Prior to commencement to Melex vehicle start or repair works it is necessary to become
familiar with the herein User's Manual. Any actions conducted out of accordance with the
Owner's Manual recommendations may result in body injuries and warranty loss.
Particular attention should be paid to the recommendations preceded with the
passwords:
WARNING
Indicates direct hazard to health.
ATTENTION
Indicates potential risk of hazard to either health or material property loss, or provides
with important directions facilitating maintanance
„*" - systems available in vehicle optional equipment
works.
1
MELEX 2021/01
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Summary of Contents for Melex 4 Series
- Page 1 Owners manual MELEX 4XX MELEX 2021/01 Prior to commencement to Melex vehicle start or repair works it is necessary to become familiar with the herein User’s Manual. Any actions conducted out of accordance with the Owner’s Manual recommendations may result in body injuries and warranty loss.
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Page 2: Table Of Contents
Owners manual MELEX 4XX MELEX 2021/01 CONTENTS: 1. INTRODUCTION ……………………………………………………………… 2. VEHICLE START AND STOP …………………………...…………………… 3. VEHICLE STEERING SYSTEM ELEMENTS………………………………… 4. DAILY MAINTENANCE……………………………………...……………….. 5. PERIODICAL MAINTENANCE………………………………………………. 5.1. Batteries……………………………………………………………..……..5.2. Cargo case…………………………………………………………………... 5.3. Sanitary equipment (model 468 ambulance – type) …………………..……. -
Page 3: Introduction
We are convinced that advantages coming out of Melex vehicle features will be confirmed in vehicle use. Prior to commencement of Melex vehicle use it is necessary to become well familiar with the herein manual that, in general, explains design of vehicle in utility version, provides directions of how safely and without failures make use of the vehicle and conduct maintenance works in the range recommended for User’s own actions. - Page 4 The maximum accessible speed during Melex vehicle towing (for exp. vehicle out of order) cannot exceed over 15 km/h. For vehicle with energy regain system, to tow it is necessary to disconnect additionally source of power from the control system by disconnecting the battery blue wire (BAT-) from battery.
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Page 5: Vehicle Start And Stop
Owners manual MELEX 4XX MELEX 2021/01 2. VEHICLE START AND STOP Starting the vehicle • Release emergency switch ( Not-Aus) placed on dashboard • Release the hand brake • Insert key into the keyswitch situated on the steering column, • Turn the key to “ON” position, •... - Page 6 Owners manual MELEX 4XX MELEX 2021/01 Stopping and leaving the vehicle with mechanical brake Drawing 2 - 1 Before leaving the vehicle it is necessary to : • Turn on the parking brake. • Turn key in the keyswitch to OFF position and remove the key.
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Page 7: Vehicle Steering System Elements
Owners manual MELEX 4XX MELEX 2021/01 3. VEHICLE STEERING SYSTEM ELEMENTS Model 4xx Models 443, 445, 463, 464, 465, 466, 468, 469 - with AC 48V system Drawing 3-1 1. Steering wheel 6. Charging receptacle 2. Keyswitch with interlock 7. Road lights switch lever 3. - Page 8 Owners manual MELEX 4XX MELEX 2021/01 Dashboard panel for models 4xx excluding 427, 447, 423, 433, 435 (version with integrated display) Drawing 3-2 1. Control panel 6. F/R switch 2. Integrated indicator 7. Slow/fast driving mode 3. Emergency switch NOT-AUS 8.
- Page 9 Owners manual MELEX 4XX MELEX 2021/01 Dashboard panel for model 427 Drawing 3-4 1. F/R switch 2. Battery discharge indicator 3. Emergency switch NOT-AUS Model 447 Drawing 3-5 1. Steering wheel 6. Charging receptacle 2. Keyswitch with interlock 7. Road lights switch lever 3.
- Page 10 Owners manual MELEX 4XX MELEX 2021/01 Dashboard panel for 447 Drawing 3-6 1. Control panel 6. Main lights switch 2. Speedometer + controlling lamps 7. Emergency lights switch 3. Battery discharge indicator 8. Slow/fast drive mode switch 4. NOT-AUS switch 9*.
- Page 11 Owners manual MELEX 4XX MELEX 2021/01 Dashboard panel 423 Drawing 3-8 1. Control panel 4. NOT-AUS switch 2. F-R switch 5. Emergency lamp switch 3. Battery discharge indicator 6. Forward direction signal switch Dashboard panel 433, 435 Drawing 3-9 1. Control panel 2.
- Page 12 Owners manual MELEX 4XX MELEX 2021/01 Integrated indicator Drawing 3-10 Drawing 3-11 1. Service button. Short pressing of given button causes displaying current time and date by 5 sec. Longer pressing the button over 4 sec. causes entering into the User’s Menu.
- Page 13 Owners manual MELEX 4XX MELEX 2021/01 Drawing 3-12 1. Batteries discharge indicator 2. Indicator of momentary batteries voltage value 3. Estimated range of vehicle for present level of batteries charging 4. Battery icon 5. Current speed indication with unit 6. Counter of total kilometers 7.
- Page 14 Owners manual MELEX 4XX MELEX 2021/01 10,1 Too fast driving – over 45 km/h 10,2 Reached range 0 km (deep discharge of batteries) Integrated indicator is equipped with acoustic signaling device which switches on in following cases: 1. Low level BDI 2.
- Page 15 Owners manual MELEX 4XX MELEX 2021/01 Speedometer with Odometer and Hourmeter Drawing 3-14 After turning key on in the keyswitch, speedometer displays the following information: 1. Number of kilometers (not cancelled – total mileage). 2. Number of kilometers (cancelled daily mileage).
- Page 16 Owners manual MELEX 4XX MELEX 2021/01 Emergency lights switching ON Switching on of emergency lights can be done using switch of emergency lights located on dashboard panel. The emergency lights can be switched on either when the ignition is on position or when the key is off the key switch.
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Page 17: Daily Maintenance
Owners manual MELEX 4XX MELEX 2021/01 3.1. Emergency Stop Not-Aus The main task of the emergency stop Not-Aus is to disconnect power of vehicle motor by disconnecting the control circuit power unit. Emergency stop, like the key-switch, switches off most of the devices on the vehicle (there are indications about way and rules of switching off in the description of each of the electrical device in this manual). - Page 18 Owners manual MELEX 4XX MELEX 2021/01 6. Connect the power plug of the charger to a power socket with a protective contact, connect the charging plug to the charging socket on the vehicle. 7. After recharge of the batteries (the charger signals the end of charging), pull the charger's plug out of the power socket, pull the charger's plug out of the charging socket.
- Page 19 Owners manual MELEX 4XX MELEX 2021/01 batteries will be greater than 0.3V (voltage measurement without load after 6 hours from the end of the charging process). During the equalization charge, you should check the electrolyte density changes every hour and unplug the charger when the density of the electrolyte no longer increases.
- Page 20 Owners manual MELEX 4XX MELEX 2021/01 of this Manual. These notes will be checked in case of warranty claim and will be the base to accept or reject the claim. • Fill and empty areometer 2-3 times before collecting proper sample;...
- Page 21 (natural or artificial ventilation with suitable anti-explosive system), equipped with doors that open outside. The site destined for the traction battery charging on Melex vehicle has to be equipped in ventilation that assures flow of fresh air stream not lower than 75 m3/h in the area of battery compartment.
- Page 22 Owners manual MELEX 4XX MELEX 2021/01 Checking of electrolyte level in lead-acid batteries If the electrolyte level before charging is below upper level of battery plate, the distilled water should be added to fully cover battery plates and after charging process refill water again so the electrolyte level will reach 12mm above upper edge of the plates.
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Page 23: Periodical Maintenance
Owners manual MELEX 4XX MELEX 2021/01 • overmuch load of vehicle; • temperature of use over 27°C; • storage temperature below 0°C in non-charged status. ATTENTION Too high or too low electrolyte level in battery will result in increased wear and decrease in vehicle range. - Page 24 Battery services must be made in special protective glasses and clothing. Additional information – lead acid batteries Melex vehicles are equipped with lead-acid batteries (Pb) or GEL. The quantity of the batteries mounted in vehicle depends of type of driving installation.
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Page 25: Cargo Case
Owners manual MELEX 4XX MELEX 2021/01 3. to storage of used up batteries in places not protected from getting through of hazardous materials into air, soil or water. 4. ejection of used batteries into containers assigned for municipal wastes 5. ejection of used batteries together with other wastes as: steel scrap, artificial materials etc. - Page 26 Owners manual MELEX 4XX MELEX 2021/01 Drawing 5-2-2 In case of aluminum cargo case, in order to adjust lock of side, you should – at open lock – turn the hook of lock (8) as many times as necessary. Drawing 5-2-3...
- Page 27 Owners manual MELEX 4XX MELEX 2021/01 1. Latch 6. Rod 2. Catch 7. Catch 3. Handle 8. Rear cargo case side 4. Bumping frame 9. Side lock 5. Bracket 10. Rotation spindle Steps for lifting the case: • Release the latch (1) and lift the case up by using the handle (3) •...
- Page 28 Owners manual MELEX 4XX MELEX 2021/01 1. Electric lifter 6. Cargo case 2. Bar 7. Cargo frame 3. Bumping block 8. Hinge 4. Shock absorber 9. Steering switch on dashboard 5. Internal covering Drawing 5-2-2-2 Lifting of cargo box is done by use the button (drawing 5-2-2-2) placed on the dashboard providing the keyswitch is on.
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Page 29: Sanitary Equipment (Model 468 Ambulance - Type)
Owners manual MELEX 4XX MELEX 2021/01 5.3 Sanitary equipment (model 468 ambulance – type) Drawing 5-3-1 1. Folding stretcher 2. Platform under folding stretcher Drawing 5-3-2 5.4 Examination of electric power installation The vehicle electric installation is equipped with the modern speed regulation system, an integral part of which is programmable speed controller suitable to collaborate with various type of AC motors. - Page 30 Owners manual MELEX 4XX MELEX 2021/01 Speed controller model 1232xx, 1234xx - with AC motor Speed controllers models 1234xx are equipped with two diodes: red and yellow (or one bicolor in 1232xx). After key-switch is on, if the controller is ready to work, the yellow diode is on (one single flash every few seconds) or error (reason) that causes the controller’s blockade and...
- Page 31 Owners manual MELEX 4XX MELEX 2021/01 Motor‘s overheating ●● ●●●●●●●● Error of motor temperature sensor (pin 8) ●● ●●●●●●●●● Short circuit or gap in the solenoid’s coil circuit (pin 6) ●●● ● Short circuit or gap in the transmitter coil of STOP lamp (pin 4) ●●●...
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Page 32: Fuse Exchange
Owners manual MELEX 4XX MELEX 2021/01 5.5. Fuses Exchange 5.5.1.Vehicle main fuse 200A (250A) Fuse is located in the batteries compartment: on the mudguard. Fuse 250A goes only with models with 5/8 kW AC motor. In the case of a blown fuse, locate and remove the cause of the fuse blown and then replace it with a new one. - Page 33 Owners manual MELEX 4XX MELEX 2021/01 5.5.3. Positions of fuses and relays in the fuse box Placing the aggregates in fuse box controller type 1232xx-xxxx/48V, 1234xx-xxxx/48V, Lighting relay: 0.2D.205.101 Full lights – MPM P-01/36-48V Turn - signals interrupter of LED lamps: 200.1H3.02...
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Page 34: Devices Of Lighting And Signaling Installations
Owners manual MELEX 4XX MELEX 2021/01 List of Fuses No of Fuse value The fuse protects socket 10 A Emergency lights and horn 7,5A turn indicator, hand brake 7,5A Road light left 7,5 A Road light - right 7,5 A Passing light –... - Page 35 Owners manual MELEX 4XX MELEX 2021/01 Model 445 Drawing 5-6-2 Model 465 Drawing 5-6-3 Model 464 and 463 (model homologated) Drawing 5-6-4...
- Page 36 Owners manual MELEX 4XX MELEX 2021/01 Model 466 Drawing 5-6-5 Model 468 ambulance-type Rys. 5-6-6 Model 469 (funeral) Drawing 5-6-7...
- Page 37 Owners manual MELEX 4XX MELEX 2021/01 Model 447 Drawing 5-6-8 Model 427 Drawing 5-6-9 Model 423 Drawing 5-6-10...
- Page 38 Owners manual MELEX 4XX MELEX 2021/01 Model 433 Drawing 5-6-11 Model 435 Drawing 5-6-12 Lamps mounted on vehicles: Type Type Description Bulb Item Homologated model Front lamp LED JUST JS- 191202 5-IN-1 Direction light 12V21W Orange P21W12V P21W12V Rear lamp (LED)
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Page 39: Side Reflective Lighting - Homologated Models
Owners manual MELEX 4XX MELEX 2021/01 Lighting, signaling and additional installation devices: Item Description Converter Fuse box Pulled hand brake switch Speedometer sensor Brake fluid level sensor Control panel STOP light switch Acoustic signal (horn) Fuse 200A (250A – motor 5 kW) -
Page 40: Examination Of Electric System
Owners manual MELEX 4XX MELEX 2021/01 Model 463 Model 463 30-860 mm 250-950 mm 5.8. Examination of electric system During periodical vehicle inspection it is necessary to check: 1. electric hoses/cables for detecting of possible damages – damage to isolation, breaks, 2. -
Page 41: Recommended Actions After Activation Of Electric Installation Protections
Short-circuit protection The particular electric installation circuits in Melex vehicle are protected against the effects of short-circuit by the means of plate fuses: 1. fuse 200A (250A) installed on the mudguard in the vehicle batteries compartment,... -
Page 42: Wheels
Despite the protections used in electric installation, any changes to function values of speed controller, change of wheels, etc. or towing inappropriate trailers with Melex vehicle may bring about to vehicle overloading and, as a consequence, to damage to drive unit. -
Page 43: Lifting Vehicle To Replace The Wheels
Owners manual MELEX 4XX MELEX 2021/01 Model / Tire 20,5x8-10 205/50-10 6PR 195/55R10C 18,5x8,50-8 423, 433, 435 F-150 R-200** F-150 R-200** F-130 R-160 F-150 R-250 F-150 R-250 F-130 R-160 443, 445 F-150 R-250** F-150 R-250** F-150 R-300 F-150 R-3005 465, 464, 466... -
Page 44: Hydraulic Brake System
5.13 Hydraulic brake system Melex vehicles assigned to riding on public streets are equipped with hydraulic brake system on all four wheels and subsidiary mechanic brake on rear wheels. Once the hand brake gets pulled, the signalling lamp of the pulled hand brake located in... -
Page 45: Mechanical Brake System
Owners manual MELEX 4XX MELEX 2021/01 ATTENTION While the hand brake is pulled out, vehicle driving system will be blocked and that will not allow to start the vehicle. Prior to refilling brake fluid, please check the hoses for detecting eventual leakages. -
Page 46: Lubrication
Owners manual MELEX 4XX MELEX 2021/01 Drawing 5-14-1 1. Bowden cable, 2. Bowden bolt, 3. Bowden nuts. 5.16 Lubrication It is necessary to conduct regular checks of the oil level in driving gear differential. The oil should be kept over the level of the filler plug located in the differential housing. If the oil level is at the same level as filler plug it is necessary to replenish it immediately: the oil HIPOL GL-5 85W/140 (1,5 liter for exchange). -
Page 47: Maintenance Works Program
Owners manual MELEX 4XX MELEX 2021/01 MAINTENANCE WORKS PROGRAM Semi- Monthly Quarterly annually Annually Every Every Maintenance work description Daily or Weekly or after or after or after or after three prior to mileage mileage of mileage of mileage of... -
Page 48: Vehicle Identification
Owners manual MELEX 4XX MELEX 2021/01 appropriately trained and authorized for examination of electric devices in compliance with the requirements obligatory in a certain country/region. 7.VEHICLE IDENTIFICATION The identification plate with identification vehicle No (VIN) is placed on the right mudguard (drawing 7-1). -
Page 49: Other Marking - Homologation
Owners manual MELEX 4XX MELEX 2021/01 Homologated Vehicles – valid from January the 1st 2017 1 – Vehicle category with subcategory 2 – Homologation number 3 – Vehicle Identification Number (VIN) 4 – Noise level 5 – Motor power 6 – Max construction speed in km/h or mph (for vehicles produced to UK) 7 –... -
Page 50: Places At Risk Of Electric Shock - Information Plate
Owners manual MELEX 4XX MELEX 2021/01 Following data are mentioned on information plate: 1- Marking of vehicle model 2 - Max permissible load on the box 3 - Permissible load on the box – for the load spread on the front half of the box 4 - Permissible load on the box –... - Page 51 Owners manual MELEX 4XX MELEX 2021/01 Placement of the plate on vehicle 1. DEFA socket Drawing 8-2-2 2. Identification of the access point to the vehicle controller and solenoid Drawing 8-2-3...
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Page 52: On-Board Charger
Owners manual MELEX 4XX MELEX 2021/01 9. ON - BOARD CHARGER On-board charger ABC 1600W with DEFA socket Charger is adapted to 48V batteries set Drawing 9-1 1. Charging signal lamp 2. Socket 230Vac of on-board charger (DEFA) 3. Power supply cable from DEFA kit... - Page 53 Owners manual MELEX 4XX MELEX 2021/01 On-board charger TCE 48V/20 AMPER with DEFA socket in vehicles 427, 447 Charger is adapted for charging of 48V batteries set (6x8V) batteries 8V 1. Charging signal lamp (located on charger) 2. Socket 230Vac of on-board charger (DEFA) 3.
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Page 54: System Of Refilling Of Electrolyte - Central System
Owners manual MELEX 4XX MELEX 2021/01 2. During disconnecting: power supply cable switch off from 230V socket first and then from vehicle. Do not charge batteries using two different chargers at the same time. 10. INSTRUCTION OF REFILLING OF ELECTROLYTE... - Page 55 Owners manual MELEX 4XX MELEX 2021/01 Refilling electrolyte level in traction batteries 1. Take off the cover protecting against soiling. 2. Connect lead pipe to HydroLink one situated in vehicle. Observe flow sensor. Red balls inside sensor start turn themselves until the moment of refilling electrolyte level 4.
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Page 56: On-Board Diagnostics
Owners manual MELEX 4XX MELEX 2021/01 11. ON-BOARD DIAGNOSTICS (OBD) In 4xx homologated vehicles, an OBD diagnostics port is installed. When OBD is connected to an external device (e.g. interface, computer tester), allows e.g. reading errors from the speed controller, erasing errors after repairing the failure, decoding basic information about the vehicle. - Page 57 Owners manual MELEX 4XX MELEX 2021/01 In case of errors, contact the service. Error message Examples of errors resulting from improper use of the vehicle: Curtis Fault HPD_SEQUENCING_FAULT P 1 0 GEAR_FAULT P 1 0...
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Page 58: Exploitation Data
Owners manual MELEX 4XX MELEX 2021/01 12. EXPLOITATION DATA Toe-in for Melex vehicles • For rim: 8”, 10” Level of emitted noise Level of noise emitted by vehicles Level of exposure for noise concerning 8-hours labor day according to standard PN-N- 01307:1994, p.2.1.1: L... -
Page 59: End Of Vehicle Exploitation
The measuring point on the tire is the tread section along the entire circumference. END OF VEHICLE EXPLOITATION Utilization After finishing of Melex vehicle exploitation it is necessary to transfer vehicle to utilization. Residual risk It is not possible to eliminate residual risk which is connected with wrong behavior by user. - Page 60 Owners manual MELEX 4XX MELEX 2021/01 fluid, cylinders (after 6 months of exploitation), tires, lubricants, oils, shock absorbers, bulbs, fuses, Complaints are also not subject to: • handbrake lever, handbrake cable, brake cams (inflection), front and rear leaf-spring - refers to damage to the above elements caused by too strong pulling of the handbrake lever;...
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Page 61: Batteries Condition Form Trojan (6V, 8V)
Owners manual MELEX 4XX MELEX 2021/01 15. BATTERIES CONDITION FORM FOR TROJAN (6V AND 8V) BATTERIES Table 1 Charging level according to electrolyte level and voltage. Charging Electrolyte Voltage level density [g/cm³] 1.277 6.37 8.49 1.258 6.31 8.41 1.238 6.31 8.41... - Page 62 Owners manual MELEX 4XX MELEX 2021/01 BATTERIES 6V – Measurement of electrolyte density and voltage Number of battery Date Number of cell Number of cell Number of cell Voltage Voltage Voltage (density [g/cm³]) (density [g/cm³]) (density [g/cm³]) Number of battery...
- Page 63 Owners manual MELEX 4XX MELEX 2021/01 BATTERIES 6V – Measurement of electrolyte density and voltage Number of battery Date Number of cell Number of cell Voltage Voltage (density [g/cm³]) (density [g/cm³]) BATTERIES 8V - Measurement of electrolyte density and voltage...
- Page 64 Owners manual MELEX 4XX MELEX 2021/01 Number of battery Number of cell Number of cell Number of cell Voltage Voltage Voltage (density [g/cm³]) (density [g/cm³]) (density [g/cm³])
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Page 65: Notes
Owners manual MELEX 4XX MELEX 2021/01 16. NOTES ______________________________________ ______________________________________ ______________________________________ ______________________________________ ______________________________________ ______________________________________ ______________________________________ ______________________________________ ______________________________________ ______________________________________ ______________________________________ ______________________________________ ______________________________________ ______________________________________ ______________________________________ ______________________________________ ______________________________________ ______________________________________ ______________________________________ ______________________________________ MELEX Sp. z o.o. ul. Inwestorów 25, 39-300 Mielec Tel. +48 17 773 81 00, fax +48 17 773 81 01 NIP: 524-25-08-288 e-mail: board@melex.com.pl,...
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