GZ10 Bed Mover Operating Manual Rev 7

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Contents Introduction ... 4 Operating Instruction... 5 Controls ... 5 Key Switch (ON / OFF) ... 5 Emergency backoff bar ... 5 Throttle grip ... 5 Speed selection ... 6 Battery level indicator ... 6 Horn (optional) ... 6

Brakes ... 6 Driving... 6 Safety check ... 6 Hitching to a bed ... 6 Controlling the Gzunda ... 7 Unhitching from a bed ... 7

Sleep Mode ... 7 Charging ... 7 Maintenance ... 8 Batteries... 8 Drive wheel ... 8 Brakes... 8 Motor ... 8 Electronic speed control... 9 Throttle lever ... 9 Fuses ... 9 Circuit breaker ... 9 Cleaning ... 10 General ... 10

Warranty ... 11 Appendices ... 12 Appendix 1 – Machine rating conditions ... 12 Appendix 2 – Fault codes ... 13 Appendix 3 – Motor brush replacement ... 14 Appendix 4 – Gzunda assembly instructions ... 15 Appendix 5 – Wiring diagram ... 18 Appendix 6 – Hitch release instructions ... 19 Appendix 7 – Charging Procedures for SLA batteries ... 20 Appendix 8 – Spare Parts List ... 24

2/14 Merri Concourse Campbellfield, VIC 3061 | phone: +613 9357 7699 | fax: +613 9357 5699 [email protected] | www.electrodrive.com.au

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Service log ... 26 Service recommendations ... 26

2/14 Merri Concourse Campbellfield, VIC 3061 | phone: +613 9357 7699 | fax: +613 9357 5699 [email protected] | www.electrodrive.com.au

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Introduction The Gzunda is a battery powered mobile towing unit to assist in the movement of heavy beds and trolleys eliminating back or shoulder strain. It is designed to save operator effort when pushing or pulling beds and trolleys. The Gzunda includes the latest developments in DC motors with automatic electromagnetic park braking, as well as a high capacity programmable controller. Features include quiet operation, ease of handling, high manoeuvrability, low maintenance, and the ability to handle heavy loads. The Gzunda slows and parks automatically when the twist grip is released. Under typical operation, the Gzunda battery capacity should be adequate for a day's operation. Overnight charging is recommended, and in high use situations additional “top-up” charging is advised. It is recommended to use the charger supplied with the Gzunda when charging the sealed maintenance free batteries. This charger is especially designed to set the charge rate, prevent gassing, and automatically cut switch to “trickle charge” when charging is complete. All bearings are pre-lubricated and sealed and should not require attention in normal use. Regular maintenance requirements on the vehicle are therefore minimal and are covered in this manual. As with any machinery, safety considerations demand that the Gzunda be handled with caution, and only operated by trained and authorised personnel. In addition, all loads must be placed securely on the bed or trolley, and the bed or trolley securely locked to the Gzunda. The Gzunda must only be operated by trained and authorised personnel.

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Operating Instruction Controls

Key Switch (ON / OFF) The key switch must be turned clockwise to switch the Gzunda on. When on, the LED status indicator will be illuminated. If a fault occurs with the electronics, this LED light will flash an error code2. It is important to note that the unit should be switched off and the key removed, whenever it is not in use. This eliminates the risk of unauthorised movement and also prevents an unnecessary use of battery power. Emergency backoff bar The emergency reverse button activates the emergency back off function. The Gzunda direction is momentarily reversed while the button is depressed. Throttle grip The throttle grip provides variable speed control. Releasing the grip stops the unit. An automatic park brake is applied after a short delay after the grip has returned to its neutral position. Under no load, the park brake will maintain the Gzunda in a stationary position. Under load, the brake 2 Refer to Appendix 2

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may not be capable of holding the system stationary – particularly on a sloping surface. Speed selection The speed selector will always start in the slow position. Select a speed that you are comfortable using. The speed can be changed whilst driving. It is advisable that the operator select a slow speed when entering a confined area. Battery level indicator The battery level indicator indicates the amount of power left in the batteries. When nearing empty, the left two (2) indicator bars will flash in an oscillating fashion. If this occurs return the Gzunda to the closest charging station to charge the batteries. Attention to the level of charge of the batteries will eliminate the possibility of running low on power whilst away from the charging station. Horn (optional) Push to sound the horn, release to turn off.

Brakes Two braking systems operate in the Gzunda. Firstly, when the throttle grip is released the Gzunda is slowed electronically with dynamic braking until the Gzunda and the accompanying load stops. In addition, after a short delay an automatic mechanical brake is activated to park the Gzunda.

Driving Safety check Before using the Gzunda to move beds the operator should complete the following feature check: (1 to 5) 1. The charger is disconnected from the Gzunda. 2. The Emergency backoff bar works 3. The battery condition indicator shows adequate charge. 4. The braking system is in operation, so that when stopped, the unit cannot be manually moved, and that the unit slowly moves when the throttle lever is gently squeezed. 5. The Gzunda hitch is not damaged and securely latches onto the bed frame. Hitching to a bed The Gzunda is fitted with an actuator controlled hitch. The hitch is controlled from the control panel. Located the Gzunda under the bed frame, ensuring that the hitch brackets align with the bed frame cross member. Raise the hitch using the “Raise” button on the control panel. When firmly attached, the hitch will stop 2/14 Merri Concourse Campbellfield, VIC 3061 | phone: +613 9357 7699 | fax: +613 9357 5699 [email protected] | www.electrodrive.com.au

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automatically [You will not be able to continue to raise the hitch]. Ensure that the Gzunda is firmly attached. Transport the bed to the desired location. Lower the hitch to release the bed. Drive the Gzunda away from the bed. To reset the hitch, momentarily lower the hitch using the “Lower” button on the control panel.

Controlling the Gzunda The Gzunda pivots about its drive wheel located at the end of the tyne. This allows the operator to position the pivot point close to the centre of the bed. Always begin in SLOW speed to ensure you maintain control of the Gzunda. The Gzunda has an intuitive control system, so it becomes easier to use the more you use it. When travelling on ramps and sloped surfaces, ensure that the bed is always on the downhill side. DO NOT LOWER THE BED INTO THE GZ10 HITCH. This may cause the safety cut-off relay to activate in a position where it can not easily be reset. Unhitching from a bed  Confirm the Gzunda and bed are stationary, and on level ground  Apply bed brakes.  Lower the hitch using the LOWER button on the control panel.  The Gzunda can now be taken to the charging station, or to the next bed. Always park the Gzunda in a safe place.

Sleep Mode After a period of 30 minutes of inactivity, the Gzunda switches into sleep mode to extend battery life. To resume operation, simply reset by turning key OFF then ON.

Charging Refer to Appendix 7 2/14 Merri Concourse Campbellfield, VIC 3061 | phone: +613 9357 7699 | fax: +613 9357 5699 [email protected] | www.electrodrive.com.au

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Maintenance Batteries If the Gzunda is not being used for an extended period of time, it should be placed on charge overnight on a regular basis – at least once a week. This will ensure the batteries are kept in good condition. The batteries are sealed and maintenance free, DO NOT attempt to open these batteries. If the Gzunda is not charged as above the batteries may become exhausted and drop below the charging threshold of the battery charger. The supplied charger cannot begin to charge the batteries unless they have a small amount of charge. If this occurs, contact Electrodrive or your local service agent. A sign that the batteries need replacing is when they no longer hold charge. Irregular charging may cause premature battery failure. Drive wheel To replace the drive wheel:  Turn off the machine and remove the key  loosen the chain by releasing the fasteners holding the gearbox in place  release the pressure from the jacking screw  remove the 4 x fasteners from the bearings adjacent to the drive wheel  lower the drive wheel assembly out from the tyne including shaft, sprocket and bearings  remove bearings from shaft and transfer to new drive wheel assembly  follow above instructions in reverse order to fit new drive wheel assembly Brakes The park brake does not require regular maintenance. If the Gzunda is not remaining stationary when in the OFF position, contact Electrodrive or your local service agent. Motor Motor brushes should be inspected every six months and replaced as required3. 3 Refer to Appendix 3 for instructions

2/14 Merri Concourse Campbellfield, VIC 3061 | phone: +613 9357 7699 | fax: +613 9357 5699 [email protected] | www.electrodrive.com.au

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Electronic speed control This unit is factory programmed, and is not serviceable by the customer. The LED status indicator on the tiller console flashes to indicate a fault with the controller. The number of flashes refers to the particular fault4. Contact Electrodrive or your local service agent for diagnosis and advice. Throttle lever The lever and cable do not require maintenance. cable suffer damage they should be replaced.

Should the lever or

Fuses The control circuit is protected against inadvertent current overloads with a 1 Amp fuse. The charger circuit is protected by a 10 amp fuse. These fuses are located next to the electronic controller on the electrical panel (see below).

Circuit breaker

Controller

Fuses (Underneath)

Batteries

Circuit breaker The Gzunda is fitted with a self resetting circuit breaker in case of momentary over-load. This switch can be found next to the fuses as shown. 4 Refer to Appendix 2 for fault codes

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If the circuit breaker continues to trip multiple times in succession, test the machine, as the motor may be damaged. Continued use could damage the unit further. The controller is also equipped with safety shut-down capabilities and will limit the battery current as well as detect low battery voltage.

Cleaning To clean exterior of machine wipe surfaces down with a warm damp cloth. A mild detergent may be used for harder to remove grime. Do NOT use chemical solvents, highly concentrated caustic soda or abrasive cleaning agents. These may damage the surface quality and may affect the integrity of polyurethane and machine lubricant properties.

General Any damage audible or visible to the Gzunda should be addressed at the time of discovery. When not in use the unit should be stored in a cool dry place. Please ensure it is not parked in a manner that obstructs access, causes a tripping hazard, or any other safety related issue.

Electrodrive can provide parts and service support on request phone +61 3 9357 7699 | fax +61 3 9357 5699 | email [email protected]

2/14 Merri Concourse Campbellfield, VIC 3061 | phone: +613 9357 7699 | fax: +613 9357 5699 [email protected] | www.electrodrive.com.au

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Warranty Electrodrive Pty. Ltd. warrants that the Gzunda is free from defects in materials and workmanship for a period of twelve months from the date of dispatch from the Electrodrive plant at Merri Concourse, Campbellfield, Victoria. If a defect is reported, Electrodrive will repair or replace the defective part, at its own discretion. This warranty does not apply if the Gzunda has been misused, damaged, or modified in any way. Please be aware that modifications and misuse will void your warranty. The following activities (including, but not limited to) are examples of these: Maintenance  The machine is re-wired by an unauthorized service agent  The motor controller is re-programmed by an unauthorized service agent  There are modifications done to the body or frame of the machine  Use of non-specified parts (Electrodrive genuine parts)  The machine is serviced by an unauthorized service agent

Misuse  Shunting loads at speeds in excess of 2.0kph  Overloading the unit either during towing or lifting  Carrying people or other foreign objects  Exposed to rain of other precipitation  Using the emergency backoff system to change direction regularly  Exposed to a corrosive environment  Driven off road – potholes, gravel, etc  Driven on slopes with a steeper gradient than 1:12  Not being charged adequately  Using E-stop as an ON/OFF button

General wear items not covered under warranty  Tyres  Tubes  Drive wheels  Hand grips  Motor brushes

If you are interested in extending your warranty period through a regular service program, please contact Electrodrive on 03 9357 7699. Note that batteries are not included. 2/14 Merri Concourse Campbellfield, VIC 3061 | phone: +613 9357 7699 | fax: +613 9357 5699 [email protected] | www.electrodrive.com.au

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Appendices Appendix 1 – Machine rating conditions The gzunda has been designed move the rated capacity on a level firm surface. Variations in the working environment may impede the performance of the gzunda. Such parameters include (but are not limited to) the following:  Ramps and sloped surfaces  Soft surfaces (for example carpet)  Slippery surfaces (gravel, water, oil etc on the ground) It is important that the gzunda NOT be operated outside of the recommended conditions.

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Appendix 2 – Fault codes Fault Code

Explanation

Causes

☼☼

over-temperature cutback

machine overloaded park brake not releasing properly short in motor or wiring high ambient temperature

☼ ☼☼

throttle pot fault

throttle pot wires open or shorted faulty throttle pot

☼ ☼☼☼

speed governor fault

speed governor wires open or shorted faulty speed governor pot

☼ ☼☼☼☼

battery voltage too low

battery voltage <17V

☼ ☼☼☼☼☼

battery voltage too high

battery voltage >36V

☼☼ ☼

main contactor controller failure

☼☼ ☼☼

contactor driver fault

☼☼☼ ☼

HPD present > 10 secs

throttle out of adjustment

☼☼☼ ☼☼

park brake fault

park brake coil open circuited controller failure

☼☼☼ ☼☼☼

precharge fault

low battery voltage controller failure

☼☼☼ ☼☼☼☼

park brake fault

park brake coil shorted controller failure

☼☼☼ ☼☼☼☼☼

high pedal disable (HPD)

throttle not in neutral when keyswitch turned on

☼☼☼☼ ☼

current sense fault

short in motor or wiring controller failure

☼☼☼☼ ☼☼

motor voltage fault

short in motor or wiring controller failure

☼☼☼☼ ☼☼☼

EEPROM fault

controller failure

☼☼☼☼ ☼☼☼☼

output section fault

short in motor or wiring controller failure

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Appendix 3 – Motor brush replacement Remove the front cover of the Gzunda

The brushes are located under the brush caps

Remove the brush caps Take out the old brushes Insert new brushes and replace brush caps

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Appendix 4 – Gzunda assembly instructions Step 1 Unfold the GZ10 until fasteners holes are aligned.

the

Step 2 Insert the supplied fasteners as shown. Include the washers supplied between the frame panels Tighten bolts

Step 3 Fit the back cover by inserting the locating tabs at the top, then lowering the panel to the body Step 4 Insert the supplied fasteners as shown. Include the ITW washers supplied between the frame panels Tighten bolts

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Step 5 Put the battery cover over the GZ10 body. “Hook” the lip of the cover over the back panel.

Step 6 “Click” the panel fasteners into place. This will secure the battery cover.

Step 7 Attach the grippers onto the hitch bar as shown.

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Step 8 Locate the grippers equally spaced. Keep them as far apart as possible to maximize load security.

The GZ10 is fully assembled ready for use.

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Appendix 5 – Wiring diagram

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Appendix 6 – Hitch release instructions The powered hitch function of the GZ10 has built in safety controls to limit the output force of the hitch. When this force is exceeded, the hitch will stop. 1. In the event of the hitch stopping unexpectedly, press the “Lower” button on the hitch controls. This resets the safety circuit, and allows the hitch to function normally. 2. If, for some reason, the hitch is overloaded in its extreme low position, there is an alternative method of “driving” the hitch out of a bind. This will only work if the hitch is in its lowest position. Whilst holding the hitch “Lower” button on the controls, press the “Raise” button simultaneously. This will momentarily override the safety circuit to get the hitch working in its normal range. Please note: These instructions should only be carried out by a competent maintenance technician. If there is any uncertainty, please contact your local Electrodrive Authorised Service Agent for further advice. To avoid the hitch being unnecessarily overloaded, please avoid lower the bed into the hitch.

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Appendix 7 – Charging Procedures for SLA batteries Always charge batteries once the job is done or day’s use is complete. Opportunity charging is NOT recommended. This can also shorten battery life. Never leave batteries in a discharged state as this will shorten the batteries life. For maximum battery life, a battery must be recharged to 100% capacity. Recharging less than 100% may result in premature battery failure. Batteries are not covered under warranty if they are not recharged properly. If batteries are not used for lengthy periods of time, it is recommended to give them a maintenance charge once every 2 months if disconnected from machine. Charging Setup Ensure you have the correct charger for the batteries. The correct voltage and current is important to ensure the full life of the batteries. Check all connections are tight and in good condition. Turn Gzunda key to ON position to begin charging. The green charger LED will illuminate to confirm charging is in progress. If charger lights do not come on, call your service technician. When charger is plugged in, drive function of machine is automatically inhibited. During Charging Ensure there is enough airflow to help keep the batteries as cool as possible. If the batteries are swollen turn off immediately and call your service technician. Always leave batteries on charge until the charge is COMPLETE. This is indicated when charger LED turns off. Charger Manual Please see charger manual overleaf for further details.

2/14 Merri Concourse Campbellfield, VIC 3061 | phone: +613 9357 7699 | fax: +613 9357 5699 [email protected] | www.electrodrive.com.au