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Melex 4 Series - User Manual

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Owners manual MELEX 4XX MELEX 2021/01
1
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 works.
„*” - systems available in vehicle optional equipment
Question and Answer IconNeed help?

Do you have a question about the Melex 4 Series and is the answer not in the manual?

Summary

Introduction and General Operation

General Safety Rules

Provides essential safety directions for using the Melex vehicle safely.

Use Limitations

Details restrictions and guidelines for vehicle usage and load capacity.

Driving in Hilly Terrain

Provides caution and recommendations for driving Melex vehicles on hilly terrain.

Vehicle Start, Stop, and Driving Techniques

Starting the Vehicle

Step-by-step guide on how to start the Melex vehicle safely.

Energy Regain System Driving Technique

Explains how to use the energy regain system for efficient driving.

Stopping and Leaving Vehicle (Hydraulic Brake)

Procedure for safely stopping and securing the vehicle with hydraulic brakes.

Stopping and Leaving Vehicle (Mechanical Brake)

Procedure for safely stopping and securing the vehicle with mechanical brakes.

Vehicle Steering System Components

Dashboard and Indicator Systems

Integrated Indicator Functions

Details the functions and signals of the integrated indicator display.

User Settings via Service Button

Guides on how users can change settings like time, date, and language.

Battery Discharge Indicator Operation

Explains the function and interpretation of the battery discharge indicator.

Vehicle Controls and Features

Speedometer, Odometer, and Hourmeter

Details the information displayed by the speedometer and odometer.

External Lights Switching

Instructions on how to operate the vehicle's external lights.

Position Lights Operation

Information on when and how to switch on the vehicle's position lights.

Emergency Lights Operation

How to activate the emergency lights from the dashboard panel.

Direction Indicators Operation

Instructions for operating the direction indicators using the steering column lever.

Horn Operation

How to activate the vehicle's horn using the steering column lever.

3-Point Safety Belts

Instructions on how to fasten and use the 3-point safety belts.

Wiper and Washer Control

How to operate the windshield wiper and washer using the steering column lever.

Daily Maintenance and Safety Checks

Emergency Stop (Not-Aus)

Explains the function and operation of the emergency stop button.

General Vehicle Technical Status Check

Checks to perform before using the vehicle for general technical status.

Lead-Acid Battery Charging Procedure

Step-by-step guide for recharging lead-acid batteries.

Battery Maintenance and Care

Equalizing Charge for Lead-Acid Batteries

Procedure for equalizing charge to maintain lead-acid battery health.

Equalizing Charge Procedure (Recommended Charger)

Detailed steps for performing an equalizing charge using a recommended charger.

Lead-Acid Battery Electrolyte Density Test

Procedure for testing electrolyte density to assess battery condition.

Checking Lead-Acid Battery Electrolyte Level

Guidance on checking and refilling electrolyte levels in lead-acid batteries.

Lead-Acid Batteries Exploitation

Tips for optimizing the use and maintenance of lead-acid batteries.

Lead-Acid Batteries Storage Conditions

Recommendations for storing lead-acid batteries to maintain their condition.

Additional Lead-Acid Battery Information

Important notes regarding lead-acid batteries, including safety and handling.

Periodical Maintenance Procedures

Cargo Case Operation

Instructions for opening, adjusting, and operating the vehicle's cargo case.

Long Cargo Case Lifting (Model 465)

Procedure for lifting the long cargo case on model 465.

Electric Cargo Case Lifting (Model 465)

How to operate the electric system for lifting the cargo case on model 465.

Sanitary Equipment (Model 468 Ambulance)

Details on the sanitary equipment fitted to the ambulance-type model.

Electric Power Installation Examination

Procedure for inspecting the vehicle's electric power installation.

Speed Controller Models (AC Motor)

Information on speed controllers for AC motors, including LED indications.

Fuse Exchange Procedures

Details on how to safely exchange fuses in the vehicle.

Fuse and Relay Box Location

Information on where to find the fuse and relay box.

Fuse Box Fuse and Relay Positions

Diagram and explanation of fuse and relay placements within the fuse box.

Lighting and Signaling Devices

Details on the vehicle's lighting and signaling components and their functions.

Side Reflective Lighting (Homologated Models)

Information and illustration for side reflective lighting on homologated models.

Electric System Examination

Checks to perform during periodical inspection of the vehicle's electric system.

Troubleshooting Common Issues

Guidance on diagnosing and resolving common vehicle problems and errors.

Overcurrent Protection

Explanation of how the speed controller protects against overcurrent.

Thermal Protection

How the controller manages temperature to prevent overheating.

Wheels and Tire Information

Details on recommended tire pressures for different vehicle models.

Lifting Vehicle for Wheel Replacement

Instructions and safety precautions for lifting the vehicle to change wheels.

Hydraulic Brake System

Description of the hydraulic brake system and its signaling lamp.

Mechanical Brake System

Information on mechanical brakes and parking brake adjustment.

Hand Brake Adjustment

Instructions for adjusting the hand brake cable for proper tension and function.

Lubrication Procedures

Guidance on checking and maintaining oil levels in the driving gear differential.

Cleaning Instructions

Recommendations for cleaning batteries and battery compartments to prevent corrosion.

Maintenance Works Program Schedule

Vehicle Identification and Markings

Vehicle Identification

Information on locating the VIN and chassis number on the vehicle.

Other Markings and Homologation Information

Details on homologation plates and additional markings on the vehicle.

Cargo Box Capacity Information Plate

Details about the information plate specifying cargo box capacity.

Electric Shock Risk Information Plates

Location and purpose of information plates indicating electric shock hazards.

On-Board Charger Operation

On-Board Charger ABC 1600 W (DEFA Socket)

Details on the ABC 1600W on-board charger with DEFA socket.

On-Board Charger TCE 48 V;25 A (DEFA Socket)

Information on the TCE 48V/25A charger for specific vehicle models.

On-Board Charger TCE 48 V;20 A (DEFA Socket)

Details of the TCE 48V/20A charger for models 427 and 447.

Battery Electrolyte Management

Electrolyte Refilling with Central Systems

General instructions for refilling electrolyte using central systems.

HydroLink System for Electrolyte Level

How to check and manage electrolyte levels using the HydroLink system.

Refilling Traction Battery Electrolyte

Step-by-step guide for refilling electrolyte levels in traction batteries.

On-Board Diagnostics (OBD) System

OBD Port Location (Homologated Models)

Details on the location of the OBD diagnostics port on homologated vehicles.

Vehicle Exploitation Data

Toe-in Specification for Melex Vehicles

Technical data regarding the toe-in alignment for Melex vehicle wheels.

Vehicle Noise Emission Levels

Data on noise levels emitted by the vehicle according to standards.

Operator Vibration Levels

Information on vibration acceleration levels affecting the operator.

Wheel Complete Specifications

Details on permissible run-out for complete wheels.

End of Vehicle Exploitation and Disposal

Vehicle Utilization Procedures

Steps to follow when transferring the vehicle for utilization after its service life.

Residual Risks During Vehicle Use

Identifies risks associated with improper user behavior and forbidden activities.

Residual Risk Assessment

How to minimize residual risks by following manual recommendations.

Parts Excluded from Warranty

Trojan Battery Condition Forms (6 V & 8 V)

Open Circuit Voltage Test (Bi-Weekly)

Procedure for testing battery voltage every two weeks to assess charge level.

Notes and Manufacturer Contact

Melex 4 Series Specifications

General IconGeneral
CategoryGolf Cars
ManufacturerMelex
Series4 Series
Battery Voltage48V
FrameSteel
Tires18x8.5-8
Battery TypeLead-Acid
SuspensionLeaf Spring
Weight450 kg (depending on configuration)
Dimensions (L x W x H)1200 mm
Standard FeaturesLights, horn, windshield

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