Foxtronics FOXCART MARK II Operation manual

FOXCARTMARKII
OPERATIONANDSERVICEMANUAL
THE POWER CART WITH MUSCLE
Revised: August, 2008
FOXTRONICS
LOVEFIELD - DALLASTEXAS
PHONE[phone]
FAX[phone]
3448 WEST MOCKINGBIRD LANE
DALLAS,TEXAS
MADE IN THE USA
UNIT WEIGHT - ALL MODELS
1200/ 1600 / 2000
APPROX.600 POUNDS

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
ThismanualprovidestheoperatingandmaintenanceproceduresfortheMarkIIseriesFoxcartGround
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 prop-
erly trained and qualified personnel only.
NOTE: The Foxcart is designed to meet Underwriter’s requirements of safety, utility and plac-
ards, 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-

MODELS
All units are provided in functional configuration with standard 15 Ft. DC cables, DC plug and 50 Ft.
AC cable with Hubbell 460P7W AC plug.
MODEL 1200
This is a single-phase power input unit and should only be considered if three-phase
power is not available. It will deliver the rated DC power, but with less efficiency and
regulation than the other models. It can handle starts on helicopters and other light
aircraft and will greatly assist a battery start on heavier aircraft.
OUTPUT VOLTS: 28 VDC
PEAK DC OUT: 1200 AMPS
CONTINUOUS DC OUT: 600 AMPS
INPUT POWER REQUIRED: 208-240 VOLTS SINGLE PHASE
200 AMPS SERVICE
MODEL 1600
This is our mid-line power unit requiring three-phase power input.
OUTPUT VOLTS: 28 VDC
PEAK DC OUT: 1600 AMPS
CONTINUOUS DC OUT: 800 AMPS
INPUT POWER REQUIRED: 208-240 VOLTS PEAK *
THREE PHASE 70 AMPS/PER PHASE
380-480 VOLTS PEAK *
THREE PHASE 50 AMPS/PER PHASE
100 AMPS SERVICE
* OTHER VOLTAGES AVAILABLE UPON REQUEST.
-3-

MODEL 2000
This is our HI-LINE unit that delivers maximum power output.
OUTPUT VOLTS: 28 VDC
PEAK DC OUT: 2000 AMPS
CONTINUOUS DC OUT: 1000 AMPS
INPUT POWER REQUIRED: 208-240 VOLTS PEAK *
THREE PHASE 100 AMPS/PER PHASE
380-480 VOLTS PEAK *
THREE PHASE 70 AMPS/PER PHASE
100 AMPS SERVICE
* OTHER VOLTAGES AVAILABLE UPON REQUEST.
60 cycle AC input current per leg at peak load for 30 seconds maximum.
MODELS 1200 1600 2000
VOLTAGE SINGLE PHASE 3 PHASE 3 PHASE
208 230 115 167
230 218 109 158
240 200 100 145
380 63 91
440 54 79
480 50 72
500 44 63
580 41 60
-4-

OPTIONS
1. EXTRA LENGTH OF AC CABLE
2. EXTRA LENGTH OF DC CABLE Lengths over 25’ not recommended.
3. SOFTSTART Limits Starting Current to 1100 AMPS to protect
engine starters and starter drive that require this
feature
4. SHIPPING CRATE
5. WEATHER PROOFING Extra protection from rain and snow
6. REVERSE CURRENT DIODES Prevents aircraft batteries from draining into the
Foxcart if power is shut off and the Foxcart is not
disconnected
7. WALL BOX RECEPTACLE KIT Wall plug to match cable plug
8. EXTRA SIZE WHEELS For rough terrain and snow
9. 14/28 VDC SWITCHING KIT Used for starting 14 or 28-volt aircraft.
10. 115 VAC UTILITY OUTLET Standard on units operating from 200-250 VAC
power source. Units operating from a higher
powersourcemusthaveastep-downtransformer
-5-

DESCRIPTION
The 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”
-6-

PREPARATION FOR USE
The Foxcart is shipped completely assembled except for the handles. Attaching hardware is in-
serted into the mounting holes where the handles are to be mounted for your convenience.
Verification of Options and Strapping should be checked before use. Incorrect Primary Supply
Voltage or Strapping could cause damage or improper DC Output.
CAUTION: WHEN THE FOXCART IS PLUGGED INTO THE AC OUTLET, ALL OF THE
STRAPPING TERMINALS ARE “HOT”. CAUTION MUST BE USED TO PRE-
VENT SHORTS OR ELECTRICAL SHOCK.
Figure 3 shows how strapping should be for different input source voltages. Select the appropriate
chart that is the same as your hangar power and compare it with the chart. If it is strapped differ-
ently correct the strapping.
The “X, Y and Z” posts are for output to the utility plug on the front of the Foxcart. To set correct
strapping, the unit must be plugged into the power source and a voltage measurement taken from
each post to case ground.
CAUTION: BEFORE RE-STRAPPING, DISCONNECT THE AC CABLE FROM THE POWER
SOURCE.
Select the post closest to 115 VAC and strap it to post “W” (See FIGURE 3)
IfyourFoxcartis380VAC or more, the StepdownTransformer should be installed.Ifnot,yourutility
outlet voltage will be high and could cause damage to equipment.
CAUTION: TERMINALS “X AND Y” WILL BE HIGH VOLTAGE.
CAUTION: IF TERMINALS “X AND Y” DO NOT READ NEAR 115 VAC, DO NOT USE THE
UTILITY PLUG. CONTACT AUTHORIZED FACTORY REPRESENTATIVE FOR
CORRECTION.
-7-

OPERATION
1. Move the Foxcart into position and set the wheel brakes.
2. Ensure that 14/28-volt selector switch is in the same voltage range as the Aircraft. (If cart is so
equipped with this optional feature).
3. Plug the Foxcart Input Power Cable into the AC Outlet.
4. Switch the Foxcart ON/OFF breaker to “ON” and rotate the Step Switch to adjust the Voltme-
ter to the desired voltage.
5. Switch the Foxcart ON/OFF breaker to “OFF” and plug the DC cable into the Aircraft DC
receptacle.
6. Switch the Foxcart ON/OFF breaker to “ON” and re-adjust the Step Switch to the desired
voltage. Ideally, there will be no current draw until the aircraft system is activated. Some
aircraft such as early Lear Jets have a direct connection between the external connection and
the battery. An internal current draw of 100 Amperes may be observed on the ammeter of the
FOXCART. This current will decrease as the batteries are charged. On this type of Aircraft,
the batteries should be allowed to charge before energizing the Aircraft electrical system.
7. Perform normal start or maintenance.
8. After starting or completion of maintenance, switch the Foxcart ON/OFF breaker to “OFF”
and disconnect the Power Cable from the Aircraft. Move the FOXCART to a safe distance
and set the brake locks to prevent movement due to Jet or Prop blast.
SOFTSTART OPERATION
Softstart provided current limiting during engine starts to prevent over-torquing starter motors and
starter drive mechanism during starts. Use this option only if your aircraft requires it.
During a Softstart, the Foxcart produces about 20% or more of the current needed for a start and the
Aircraft batteries supply the remaining current. If the Aircraft design maintains the ship’s batteries on
line, the FOXCART will supply all the power. After start, if the FOXCART is left on line long enough,
it will recharge the Aircraft batteries.
-8-

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.
-9-

TROUBLESHOOTING
If the Foxcart does not deliver the proper DC output, check the strapping using the procedure
outlined on Page 7.
If the Foxcart has been operational for a period of time and has failed, use the following steps to
assist in isolating the problem. If the problem cannot be isolated, please call Foxtronics for
assistance. The phone number is [phone]. Replacement parts may be ordered from the
same number.
1. Test the wall receptacle for proper voltage.
2. Using DMM, measure the voltage at the end of the DC Cable. Does the measure-
ment agree with for Foxcart voltmeter?
3. Remove the Strapboard Access Cover. (See Figure 2, Item 4.)
CAUTION, SHOCK HAZARD: WHEN THE INPUT CABLE IS PLUGGED INTO THE WALL
RECEPTACLE, HIGH VOLTAGES ARE PRESENT AT THE STRAPPING TERMINALS.
THESE VOLTAGES MAY BE LETHAL.
A. Plug theAC cable into wall receptacle.
B. Turn on Foxcart power.
C. Test the voltage between Terminal “Ato C and “Ato E” and “C to E”.All
should be the same voltage. The voltage should also be the same as your
wallvoltage.
D. If step C is incorrect, the problem is between the wall and the input
strapboard.
E. Turn OFF the Foxcart power.
F. Remove the AC cable from the wall receptacle.
G. Using DMM, measure the resistance between theAC plug and the input
strapboard.AllreadingsshouldbeINFINITE.
H. With the AC plug still removed from the wall receptacle, turn on main
Foxcart circuit breaker. Measure resistance betweenAC plug and input
strap board. Resistance should be close to zero. The ground pin should
read continuity to the Foxcart chassis.
4. If problem is still not found:
ENSURE FOXCART IS DISCONNECTED FROM THE WALL RECEPTACLE.
A. Remove top cover.
-10-

B. Inspect the interior of the Foxcart for any signs of arcing or burning, such
as wires or connections.
C. Remove rectifier bus bars and any attaching wiring.
D. Using a DMM Diode Tester, test all the diodes.All readings should be
similar in the forward direction and infinite in the reverse direction.
E. Remove buss bars and attaching wires from reverse current diodes. Test
as in step D. Note, the reverse current diodes are the opposite polarity.
F. Inspect the blue filter capacitors and wiring for leakage or burnt wires.
G. Reassemble the Foxcart.
-11-

FIGURES / DIAGRAMS
FIGURE 1 FOXCART DIMENTIONS
FIGURE 2 FRONT PANEL COMPONENTS
FIGURE 3 STRAPPING CHART
FIGURE 4 MAJOR COMPONENTS
FIGURE 5 MODEL 1200B w/REVERSE CURRENT
FIGURE 6 MODEL 1600B/2000B w/REVERSE CURRENT &
SOTFSTART
FIGURE 7 MODEL 1600B/2000B w/14/28VDC OPTION
FIGURE 8 MODEL 1600B/2000B w/STEPDOWN
TRANSFORMER
FIGURE 9 AC CONNECTOR WIRE HOOK-UP
FIGURE 10 460P7W HUBBELL PLUG DIMENTIONS
-12-

FOXCART MARK II
DIMENSIONS
50.5
DIMENSIONS ACROSS HANDLES
31.0
BOX DIMENSION
HANDLE HEIGHT
ABOVE GROUND
BOX HEIGHT
20.0
BOX DIMENSION
GROUND LEVEL
30.0
OUTSIDE WHEELS DIMENSION
21.0
BOX DIMENSION
UNIT WEIGHT − ALL MODELS
1200/1600/2000
APPROX. 600 POUNDS
31.5
25.5
FIGURE 1.

3448 W. Mockingbird Ln.
Dallas, TX 75235
PHONE: [phone]
FAX: [phone]
TITLE: FOXCART FRONT PANEL COMPONENTS
DRAWING NO: 400-
0001-007
PAGE: 1 OF 1 REV: B
DRAWN BY: SE APPROVED BY:
DATE:
10/01/01
SOFT
START
DC
VOLTAGE
ADJUST
DC
VOLTS
DC
AMPHRES
HILO
ITEM DESCRIPTION
INPUT POWER STRAPPING PANEL
INPUT POWER STRAPPING
15 AMP FUSE
COVER PLATE
UTILITY 115 VOLT STRAPPING
GREEN POWER "ON" INDICATOR
REVERSE DIODES OPTION, RED
AMPMETER RANGE SWITCH
AMPMETER
VOLT METER
14 VOLT "ON" LIGHT, WHITE
UTILITY 115 VOLT BREAKER
115 VOLT UTILITY RECEPTACLE
OPTION, SOFT START SWITCH
VOLT STEP SWITCH
NAME PLATE
14/28 VOLT OPTION
POWER SWITCH & BREAKER
OUTPUT
LOAD
NORMAL
AMPMETER RANGE
FIGURE 2.
foxtronics
incorporated
1
2
3
4
5
6
7
8
9
11
10
12
13
14
15
16
17
18
9
8
12
13
14
15
16
17
18
11
10
7
6
5
4
3
2
1

3448 W. Mockingbird Ln.
Dallas, TX 75235
PHONE: [phone]
FAX: [phone]
TITLE: FOXCART AC INPUT VOLTAGE STRAPPING
DRAWING NO: 400-0001-003
PAGE: 1 OF 1 REV: B
DRAWN BY: SE APPROVED BY:
DATE: 10/01/01
208
230
240
FOXCART MODEL 1200
2
34
B
2
34
2
34
EF
208V
2
34
B
2
34
2
34
EF
230V
2
34
B
2
34
2
34
EF
240V
2
34
B
2
34
2
34
EF
380V
2
34
B
2
34
2
34
EF
440V
2
34
B
2
34
2
34
EF
480V
FOXCART MODEL 1600/2000
2
34
B
2
34
2
34
EF
208V
2
34
B
2
34
2
34
EF
225V
2
34
B
2
34
2
34
EF
440V
2
34
B
2
34
2
34
EF
480V
FOXCART MODEL 1600-C ONLY
208 TO 250 VAC LINE
15 AMP FUSES
UTILITY PLUG SET-UP
PLUG THE INPUT CABLE OF THE FOXCART INTO HANGAR POWER. USING A VOLTMETER, CHECK THE VOLTAGE AT
TERMINALS "X" AND "Y" TO CHASSIS GROUND. SELECT THE MEASUREMENT THAT IS NEAREST TO 120 VAC.
DISCONNECT HANGAR POWER, CONNECT STRAP BETWEEN SELECTED TERMINAL AND POST "W" TIGHTEN NUTS,
RECONNECT POWER AND VERIFY THAT 120 VAC IS AT THE UTILITY PLUG.
NOTE: IF INPUT AC POWER IS 380 VAC OR ABOVE AND STEPDOWN TRANSFORMER IS INSTALLED. TERMINALS W, W,
Y AND Z ARE DISCONNECTED.
FIGURE 3.
foxtronics
incorporated Y
X
W
Z
1
1
1
1
1
11
1
1
11
11
1
1
1
1
1
1
1
1
1
11
1
1
1
1
1
A
A
C
C
D
D
A
CD
D
C
A
A
CD
D
C
A
A
CDD
C
A
AA
CC
D D

3448 W. Mockingbird Ln. Dallas, TX 75235 PHONE: [phone] FAX: [phone]
TITLE: FOXCART COMPONENT PARTS
DRAWING NO: 400-0001-005
PAGE: 1 OF 1
REV: B
DRAWN BY: SE
APPROVED BY:
DATE: 10/01/01
ITEM DESCRIPTION
ON/OFF BREAKER
VOLT METER
LIGHT (GREEN) POWER ON
STEP SWITCH
LIGHT (RED) REVERSE CURRENT
14/28 VDC SWITCH
SOFT START SWITCH
AC RECEPTICLE
AMPMETER
SERVICE PLUG CIRCUIT BREAKER
TRANSFORMER
AMMETER SHUNT
RIGHT DIODE PLATE ASSEMBLY
STABILIZING RESISTOR SOFT START
CAPACITOR (40,000 MF)
REVERSE DIODES
FAN ASSEMBLY
DIODE
MOUNT FAN
AMPMETER RANGE SWITCH
INPUT STRAP BOARD
STEP-DOWN TRANSFORMER
(CONDENSER) 2 MF CAPACITOR
CHOKE
LEFT DIODE PLATE ASSEMBLY LIGHT (WHITE) 14VDC ON
26
25
24
4
22
23
20
27
FIGURE 4.
foxtronics
incorporated
15
14
13
12
11
21
17
19
18
16
6
1
2
3
7
8
10
9
5
19
27 26 25
24 23 22 21
20 11
18 17
16
15 14 13
12
9
8 7 6 5 4
3 2 1
10

GRN
VOLTS
-
+
AMPS
-
+
X
Z
RED
-
+
CHOKE
LOW
NORMAL
SHUNT
240 230 208
10A
115V SERVICE
1 K.V.A. MAX
CORRECT FAN MOTOR WIRING TO BE
COMPATIABLE WITH EITHER 240/480VAC
INPUT
15A
OPTIONAL REVERSE
CURRENT
DIODES
METER RANGE SWITCH
THIS DRAWING IS APPLICABLE TO ALL 1200 FOXCARTS
WITH -A S/N's AND 1200B SERIES.
3448 W. Mockingbird Ln. Dallas, TX 75235 PHONE: [phone] FAX: [phone]
TITLE: 1200 FOXCART w/REVERSE CURRENT DIODE
DRAWING NO: 400 0005 002
PAGE: 1 OF 1 REV: B
DRAWN BY: SE APPROVED BY:
DATE: OCTOBER 8, 2001
++
+
+
+
-
-
-
-
-
FAN
230V
100A
BLACK
WHITE
GREEN
1
2
3
4
5
6
71
2
3
4
5
6
7
15A
.9
FIGURE 5.
1
foxtronics
incorporated
W
Y
1

1600/2000 FOXCART
3448 W. Mockingbird Ln. Dallas, TX 75235 PHONE: [phone] FAX: [phone]
TITLE:
DRAWING
NO:
PAGE: 1 OF 1 REV: B
DRAWN BY: SE APPROVED BY:
400-0005-018/028 DATE: 10/09/01
GRN
VOLTS
-
+
AMPS
-
+
7
6
5
4
3
2
1
B-
4
1
2
3
7
6
5
4
3
2
1
D-
4
1
2
3
7
6
5
4
3
2
1
EF-
4
1
2
3
X
Z
GREEN
WHITE
BLACK
RED
RED
-
+
CHOKE
40,000 mf
SOFTSTART NORMAL
OPTIONAL
SOFTSTART
LOW
NORMAL
SHUNT
302UR(xx)X
LEFT SINK
T1
T2
T3
1234480
240 230
208
480
480
1 2 3 4
1 2 3 4
230V
FAN 50 OR 60 Hz
70A FOR 1600
100A FOR 2000
10A
4 COND #6 CABLE
115V SERVICE 1 K.V.A. MAX
NOTE: FOR USE WITH 380VAC INPUT OR ABOVE STEP-DOWN TRANSFORMER IS REQUIRED
14V TAPS ON M2000
TRANSFORMER ONLY
CORRECT FAN MOTOR WIRING TO BE COMPATIABLE WITH EITHER 240/480VAC
INPUT
1
2
240 230
208
240 230
208
W
15A
15A
1
RIGHT SINK
OPTIONAL REVERSE CURRENT
DIODES
++
METER RANGE SWITCH
2
2
2
2
2
2
THIS DRAWING IS APPLICABLE TO ALL 1600/2000
FOXCARTS WITH -A S/N's AND 1600B/2000B SERIES.
W/REVERSE CURRENT DIODE & SOFTSTART
FIGURE 6.
foxtronics
incorporated
Y
A
C