FOXCART 400 MARK II OPERATION AND SERVICE MANUAL MODEL PR2400-400 APPROX. 550POUNDS THE POWER CART WITH MUSCLE FOXTRONICS LOVE FIELD - DALLAS TEXAS MADE IN THE USA 3448 WEST MOCKINGBIRD LANE DALLAS, TEXAS PHONE (214) 358-4425 FAX (214) 358-1519 APRIL, 2004 Rev. A
TABLE OF CONTENTS PAGE 1. AN OVERVIEW 1. 2. PURPOSE OF EQUIPMENT 2. 3. MODELS 3.-4. 4. OPTIONS 5. 5. DESCRIPTION 6. 6. PREPARATION FOR USE 7. 7. OPERATION 8. 8. PREVENTIVE MAINTENANCE 9. 9. TROUBLESHOOTING 10.-11. 10. FIGURES / DIAGRAMS 12. 11. APPENDIX A 12. APPENDIX B
AN OVERVIEW This manual provides the operating and maintenance procedures for the Mark II series Foxcart Ground Power Units. The first part of this manual covers operating procedures that are typical for aircraft Ground Power Units operating from an alternating current source. Preparation for use and routine maintenance are also covered. The second part is addressed to trained technical personnel qualified to perform the detailed process of electrical configuration, problem analysis and repair. Applicable drawings, charts and schematic wiring diagrams are provided and referenced in the text to identify components and test points with typical voltage and resistance measurements. Due to the potentially lethal voltages, it is mandatory that the units described herein be operated and maintained by properly trained and qualified personnel only. NOTE: The Foxcart is designed to meet Underwriter s requirements of safety, utility and placards, even though UL specifications are not directed to this type of device. -1-
PURPOSE OF EQUIPMENT The Foxcart ground power unit is designed to provide smooth, high current DC power to aircraft during engine starts or ground maintenance. The Foxcart, when used as an external DC source, eliminates or minimizes excessive current drain from the aircraft s battery and battery relay contacts. It is also designed as a low profile unit that requires minimum ventilation and is easily moved in a crowded hangar by one person. -2-
MODEL PR2400-400 OUTPUT VOLTS: PEAK DC OUT: CONTINUOUS DC OUT: INPUT POWER REQUIRED: 28 VDC 1600 AMPS 800 AMPS 200 VAC 3 PHASE -3-
OPTIONS 1. WEATHER PROOFING Extra protection from rain and snow -4-
DESCRIPTIONThe Foxcart is enclosed in an all-steel chassis frame with a three-piece steel box siding. The power cables can be wrapped around the handles or coiled on top for storage. The wheels can be locked in place to prevent movement. Both power cables are clamped internally to the frame for strain relief. Location and identification of the controls are shown in Figure 2. The controls marked optional are not included in the standard Foxcart unless ordered by the customer. DIMENSIONS INCLUDING HANDLES: See FIGURE 1 STANDARD FOXCART: Length 39.00 Width 21.50 Height 16.50 WITH TERRAIN WHEELS: Length 39.00 Width 21.50 Height 21.50-5-
PREPARATION FOR USE The Foxcart is shipped completely assembled except for the handles. Attaching hardware is inserted into the mounting holes where the handles are to be mounted for your convenience. Verification of Options should be checked before use. Incorrect Primary Supply Voltage could cause damage or improper DC Output. CAUTION: WHEN THE FOXCART IS PLUGGED INTO THE AC OUTLET. CAUTION MUST BE USED TO PREVENT SHORTS OR ELECTRICAL SHOCK. -6-
OPERATION 1. Move the Foxcart into position and set the wheel brakes if available. NOTE: Wheel brakes not available on units with rough terrain kits (Large Tires/Casters). These units must be chocked. 2. Plug AC Cable into Foxcart. 3. Turn main power circuit breaker on Foxcart to the ON (up) position. 4. Connect DC power cable to aircraft. 5. Power up AC power cart and apply power to Foxcart. 6. Rotate the Step Switch and set the Foxcart out put voltage to desired voltage. 7. Turn on aircraft external power. 8. Upon completion of aircraft maintenance on start, reverse steps for shutdown. CAUTION! SHOCK HAZARD When AC power is applied to Foxcart and the main On/Off circuit breaker is in the ON (up) position, DC voltage is present at DC cable contacts. -7-
PREVENTIVE MAINTENANCE Routine maintenance should be performed periodically. Since the wheels and fan motor are the only moving parts on the Foxcart, maintenance is kept to a minimum. 1. Oil fan motor and all other moveable parts. 2. Using compressed air and a dry cloth, clean accumulated dust and grime from unit. 3. Perform visual inspection and tighten any loose nuts and bolts. 4. Inspect cables and plugs for cuts, cracks or deterioration. -8-
TROUBLESHOOTING If the Foxcart has been operational for a period of time and has failed, use the following steps to correct the problem. If the problem still cannot be isolated, please call Foxtronics for additional help. The phone number is (214) 358-4425. Replacement parts may be ordered from the same number. 1. Check the wall plug and circuit breakers for proper voltage. CAUTION: WHEN THE INPUT CABLE IS PLUGGED INTO THE AC OUTLET, HIGH VOLT- AGES ARE PRESENT. THESE VOLTAGES MAY BE LETHAL. F. Remove the Foxcart cover to gain access to the inside. CAUTION: DISCONNECT POWER CABLE FROM AC POWER SOURCE. 1. Remove the wires and Bus Bars from the transformer to the diodes. a. Check the resistance across the diodes. They should read about 12 ohms one way and infinite with the leads reversed. We recommend if one is found defective, then all diodes on the bank be replaced. A. Plug the input cable into the AC outlet. B. Check the voltage at ON/OFF Circuit Breaker to see they are the same voltage as the AC outlet. C. If they are not, the problem is between the AC outlet and the Circuit Breaker. D. Check the voltage across the DC meter. The readings should be the same. If the FOXCART s DC meter reads low, replace it. E. Disconnect the input plug from the AC outlet. 1. Using a Multimeter, (use an analog meter not a digital meter), check the resistance from breaker,) ohms should be measured. If not, the problem is in the input cable or plug, it should be repaired or replaced. 2. Switch the ON/OFF breaker ON and measure the resistance across the switch. 0 ohms should be measured across each contact. If not, replace the switch. 3. Measure the resistance from the output of the switch to the TAP Switch Center Terminal. Zero (0) ohms should be measured. If not, repair or replace the wire that is defective. -9-
b. The diodes on each bank are of different polarity, positive and negative. When ordering, be certain the correct ones are ordered. c. If the diodes check good, reconnect the wires. G. Check the capacitors to be sure they are good and the wiring is in good condition. -10-
FIGURES / DIAGRAMS FIGURE 1 FIGURE 2 FIGURE 3 FIGURE 4 FIGURE 5 FOXCART DIMENSIONS FRONT PANEL COMPONENTS MAJOR COMPONENTS PR2400-400 SCHEMATIC PARTS LIST -11-
FOXCART MARK II DIMENSIONS 50.5 DIMENSIONS ACROSS HANDLES HANDLE HEIGHT ABOVE GROUND BOX HEIGHT 20.0 BOX DIMENSION 31.5 31.0 BOX DIMENSION 25.5 21.0 BOX DIMENSION 30.0 OUTSIDE WHEELS DIMENSION GROUND LEVEL UNIT WEIGHT ALL MODELS 1200/1600/2000 APPROX. 600 POUNDS FIGURE 1.
18 10 17 DC VOLTS 11 6 FIGURE 2. DC VOLTAGE ADJUST 7 16 OUTPUT LOAD NORMAL SOFT START 15 14 DC AMPHRES LO HI AMPMETER RANGE 12 8 9 13 18 17 16 15 14 13 12 11 10 9 8 7 6 POWER SWITCH & BREAKER 14/28 VOLT OPTION NAME PLATE VOLT STEP SWITCH OPTION, SOFT START SWITCH 115 VOLT UTILITY RECEPTACLE UTILITY 115 VOLT BREAKER 14 VOLT "ON" LIGHT, WHITE VOLT METER AMPMETER AMPMETER RANGE SWITCH REVERSE DIODES OPTION, RED GREEN POWER "ON" INDICATOR ITEM DESCRIPTION foxtronics incorporated 3448 W. Mockingbird Ln. Dallas, TX 75235 PHONE: 214/358-4425 FAX: 214/358-1519 TITLE: FOXCART FRONT PANEL COMPONENTS DRAWING NO: 400-0001-007 DATE: 10/01/01 PAGE: 1 OF 1 REV: B DRAWN BY: SE APPROVED BY:
23 18 19 17 16 21 20 22 FIGURE 3. 11 15 14 26 6 1 25 2 3 13 12 4 7 8 9 24 5 10 26 STEP-DOWN TRANSFORMER 25 LIGHT (WHITE) 14VDC ON 24 AMPMETER RANGE SWITCH 23 MOUNT FAN 22 DIODE 21 LEFT DIODE PLATE ASSEMBLY 20 CHOKE 19 (CONDENSER) 2 MF CAPACITOR 18 FAN ASSEMBLY 17 REVERSE DIODES 16 CAPACITOR (40,000 MF) 15 SOFT START 14 STABILIZING RESISTOR 13 RIGHT DIODE PLATE ASSEMBLY 12 AMMETER SHUNT 11 TRANSFORMER 10 SERVICE PLUG CIRCUIT BREAKER 9 AMPMETER 8 AC RECEPTICLE 7 SOFT START SWITCH 6 14/28 VDC SWITCH 5 LIGHT (RED) REVERSE CURRENT 4 STEP SWITCH 3 LIGHT (GREEN) POWER ON 2 VOLT METER 1 ON/OFF BREAKER ITEM DESCRIPTION foxtronics incorporated 3448 W. Mockingbird Ln. Dallas, TX 75235 PHONE: 214/358-4425 FAX: 214/358-1519 TITLE: FOXCART COMPONENT PARTS DRAWING NO: 400-0001-005 DATE: 10/01/01 APPROVED BY: REV: B DRAWN BY: SE PAGE: 1 OF 1
B D F 7 1 7 1 7 1 6 5 4 2 3 6 5 4 2 3 6 5 4 2 3 200 VAC 200 VAC 200 VAC T1 T2 T3 400 Hz G R W B 400 Hz 28vdc CHOKE NEGATIVE DIODE 302UR60 FAN + + 40,000 mf GRN AMPS + 1000a METER RANGE SWITCH LOW 2000a NORMAL SHUNT 750a 50mv + + VOLTS - foxtronics INC. TITLE: PR2400/400 3448 W. Mockingbird Ln. Dallas, TX 75235 PHONE: 214/358-4425 FAX: 214/358-1519 DRAWING NO: 400-0005-030 PAGE: 1 OF 1 REV: B DATE: 07/03/03 DRAWN BY: SE APPROVED BY: - - RED BLACK WHITE
ASSEMBLY: MODEL PR2400-400 COMPONENTS DESCRIPTION UNITS REQ. ASSEMBLY COMPONENTS DESCRIPTION UNITS REQ. ASSEMBLY 401-0001-016 412-7-T2 TAP SWITCH 1.0 NO 401-0004-016 TRIPLET / DC VOLT METER 0-40VDC 1.0 NO 401-0005-016 DC AMP METER: DUAL 1.0 NO 401-0009-016 502-3241-102 LT/ASY 1.0 NO 401-0009-017 LAMP. TYPE 313 1.0 NO 401-0010-016 LENSE GREEN 320112300 1.0 NO 401-0013-016 700A/50mv SHUNT; HA750-50 1.0 NO 401-0015-001 75 OHM, 5W, RESIST. PW5-75 1.0 NO 401-0019-016 CGS4030040X4C/40,000MF 40V 2.0 NO 401-0019-017 CLAMP VR12B (3 ) 2.0 NO 401-0020-020 CHOKE; MOD 2000 1.0 NO 401-0021-040 TRANSFORMER/2000-400 1.0 NO 401-0023-001 FR/PL, PLATE 8 X 8 1.0 NO 401-0023-005 FRONT PNL (NEW-DWG) 1.0 NO 401-0023-013 CHASSIS FRAME 1.0 NO 401-0023-016 COVER 1.0 NO 401-0023-018 PLATE RE-ENFORCE 2.0 NO 401-0023-019 HANDLE, FOXC 1.0 NO 401-0023-021 REAR PANEL 1.0 NO 401-0026-001 PILLOW BLK 2X530 x ¾ 2.0 NO 401-0026-003 SHAFT COLLAR 2 x 570 x ¾ 2.0 NO 401-0041-001 DIAL KNOB # 5152A 1.0 NO 401-0041-002 VOLT-ADJ DECAL 1.0 NO 401-0041-003 5003/1-7/DIAL/IND/PLATE 1.0 NO 401-0052-002 CABLE ASSEMBLY/DC, 25FT/W/PLUG 1.0 NO 401-0068-011 DECAL, FOXCART S/N MODEL, PR2400-400 1.0 NO 401-0068-003 DECAL, FOXCART LOGO 2.0 NO 401-0068-006 DECAL, CAUTION 1.0 NO 401-0068-007 DECAL, HI / LO (AMP) 1.0 NO 401-0071-002 SWITCH, TOGGLE #93-4001SPSTON/MO 1.0 NO 402-0045-002 CBL/AC SO90 C-P123-70MSHA o 4 50.0 NO 404-1600-010 LOAD RESISTOR 1.0 YES 404-1600-002 LEFT DIODE PLATE 1.0 YES 404-1600-004 RIGHT DIODE PLATE 1.0 YES 401-0002-017 FAN 1.0 NO 401-0023-017 FAN BRACKET 2.0 NO 405-0002-002 TOW BAR, UNITED A/C 1.0 NO 401-0053-007 RECEPTICLE 1.0 NO 401-0006-014 BLANK OFF PLATE 1.0 NO 401-0027-019 CASTER, LARGE 2.0 NO 401-0027-017 AXEL, LONG 3/4 x 30 3/4 1.0 NO 401-0027-018 TIRE 16 2.0 NO 401-0023-023 FENDER 2.0 NO
ASSEMBLY: 50 Hz OPTION APPENDIX A-4 COMPONENTS DESCRIPTION UNITS REQ. ASSEMBLY COMPONENTS DESCRIPTION UNITS REQ. ASSEMBLY 401-0003-018 3M459 FAN MOTOR 50Hz 1.0 NO 401-0003-019 3M492 MOUNT 1.0 NO 401-0003-020 SPLIT RING ADAPTOR 1.0 NO ASSEMBLY: SOFTSTART OPTION COMPONENTS DESCRIPTION UNITS REQ. ASSEMBLY COMPONENTS DESCRIPTION UNITS REQ. ASSEMBLY 401-0045-003 CABLE, (DC) WELDING TYPE 2/0 5.0 NO 401-0068-008 DECAL, SOFT START 1.0 NO 401-0071-004 TOG/SWITCH C/H #8792K3 SOFT-START 1.0 NO 401-1023-000 YELLOW 2/0 322090 (2J1871) 2.0 NO 402-1022-000 YELLOW 2/0 322089 (ZZ251869) 6.0 NO 404-0004-000 SOFT START GRID 1.0 NO ASSEMBLY: REVERSE CURRENT OPTION COMPONENTS DESCRIPTION UNITS REQ. ASSEMBLY COMPONENTS DESCRIPTION UNITS REQ. ASSEMBLY 401-0009-016 502-3241-102 LT/ASY 2.0 NO 401-0009-017 LAMP TYPE 313 2.0 NO 401-0010-017 LENSE, RED #25F-1576 1.0 NO 401-0015-001 75 OHM, 5W, RESISTOR PW5-75 2.0 NO 401-0016-001 302U10A POS DIODE; REV/CUR 3.0 NO 402-0046-005 18 GA WIRE 5.0 NO 402-1014-000 BLUE #10 36160 2.0 NO 402-1020-002 RED 3/8 31897 1.0 NO