Melex 465 - User Manual

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

Summary

2. Vehicle Start and Stop

Starting the Vehicle

Steps to safely start the Melex vehicle.

Stopping and Leaving with Hydraulic Brake

Procedures for stopping and securing the vehicle with hydraulic brakes.

Stopping and Leaving with Mechanical Brake

Integrated Indicator Functions

Indicator Display Elements

Battery Discharge Indicator

Speedometer and Lighting Controls

Speedometer, Odometer, and Hourmeter Display

Vehicle Controls and Safety Features

3-Point Safety Belts

Instructions for fastening the 3-point safety belts.

3.1. Emergency Stop Not-Aus

4. Daily Maintenance

Checking Vehicle Status

Pre-use checks for vehicle technical condition.

Charging Lead-Acid Batteries

Steps for recharging lead-acid batteries.

Equalizing Charging of Lead-Acid Batteries

Equalizing Charge Procedure

Testing Lead-Acid Battery Electrolyte Density

Checking Electrolyte Level in Lead-Acid Batteries

Lead-Acid Batteries Exploitation

5. Periodical Maintenance

5.1. Batteries

Lead-Acid Batteries

5.4. Examination of Electric Power Installation

Speed Controller Models 1232 xx, 1234 xx with AC Motor

5.5. Fuses Exchange

5.5.1. Vehicle Main Fuse 200 A (250 A)

5.5.2. Fuse-and-Relay Box Location

5.5.3. Positions of Fuses and Relays in the Fuse Box

List of Fuses

5.8. Examination of Electric System

5.9. Troubleshooting

Unexpected Vehicle Stops During Drive

Checks to perform when the vehicle stops unexpectedly.

Vehicle Slowdown or Stops with Heavy Load

Checks for issues when driving with heavy loads.

Vehicle Drives Slowly

Vehicle Stops or Jerks During Drive

5.10. Recommended Actions After Electric Installation Protection Activation

Troubleshooting Common Issues

Steps for diagnosing and resolving slow driving, jerky stops, lighting, horn, and wiper failures.

Short-Circuit Protection

Overcurrent Protection

Thermal Protection

5.11. Wheels

5.12. Lifting Vehicle to Replace Wheels

Lifting Vehicle for Front Wheel Exchange

Lifting Vehicle for Rear Wheel Exchange

5.13. Hydraulic Brake System

Checking Brake Fluid Level

5.14. Mechanical Brake System

5.15. Hand Brake

6. Maintenance Works Program

8.2. Information Plate - Places of Electric Shock Risk

Plate Placement on Vehicle (Electric Shock Risk)

9. On-Board Charger

On-Board Charger ABC 1600 W with DEFA Socket

Details on the ABC 1600W charger.

On-Board Charger TCE 48 V;25 A (Excluding Models 427, 447)

Details on TCE 48V/25A charger for specific models.

On-Board Charger TCE 48 V;20 A (Models 427, 447)

10. Electrolyte Level Refilling Using Central Systems

10.1. System Hydrolink

Using the Hydrolink system for electrolyte refilling.

Refilling Electrolyte Level in Traction Batteries

11. On-Board Diagnostics (OBD)

OBD Location (Homologated Models)

OBD Location (Model 4 xx under Dashboard)

Error Message Display

How error messages appear on the integrated indicator.

Error Message Interpretation

15. Batteries Condition Form for Trojan (6 V and 8 V) Batteries

Voltage Test of Open Circuit (Every 2 Weeks)

6 V Batteries: Electrolyte Density and Voltage Measurement

6 V Batteries: Measurement Data Recording

8 V Batteries: Measurement Data Recording

Melex 465 Specifications