Foxcart MKII Manual

FOXCART MARK II
OPERATION AND SERVICE MANUAL
UNIT WEIGHT - ALL MODELS

1200 / 1600 / 2000
APPROX. 600 POUNDS
THE POWER CART WITH MUSCLE
FOXTRONICS
LOVE FIELD - DALLAS TEXAS
MADE IN THE USA
3448 WEST MOCKINGBIRD LANE

DALLAS, TEXAS
Revised: August, 2008
PHONE (214) 358-4425

FAX (214) 358-1519
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 Underwriters 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 aircrafts 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:
PEAK DC OUT:
CONTINUOUS DC OUT:
INPUT POWER REQUIRED:
28 VDC
1200 AMPS
600 AMPS
208-240 VOLTS SINGLE PHASE
200 AMPS SERVICE
MODEL 1600
This is our mid-line power unit requiring three-phase power input.
OUTPUT VOLTS:
PEAK DC OUT:
CONTINUOUS DC OUT:
28 VDC
1600 AMPS
800 AMPS
208-240 VOLTS PEAK *
THREE PHASE 70 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:
PEAK DC OUT:
CONTINUOUS DC OUT:
28 VDC
2000 AMPS
1000 AMPS
100 AMPS SERVICE
OTHER VOLTAGES AVAILABLE UPON REQUEST.
60 cycle AC input current per leg at peak load for 30 seconds maximum.
MODELS
VOLTAGE
208
230
240
1200
1600
2000
SINGLE PHASE
230
218
200
3 PHASE
115
109
100
3 PHASE
167
158
145
63
54
50
44
41
91
79
72
63
60
380
440
480
500
580
-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
power source must have a step-down transformer
-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:
WITH TERRAIN WHEELS:
Length
39.00
Width
Height
21.50
16.50
Length
39.00
Width
Height
21.50
21.50
-6-
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 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 PREVENT 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 differently 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)
If your Foxcart is 380 VAC or more, the Stepdown Transformer should be installed. If not, your utility
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.
4.
Plug the Foxcart Input Power Cable into the AC Outlet.

Switch the Foxcart ON/OFF breaker to ON and rotate the Step Switch to adjust the Voltme-
5.
ter to the desired voltage.

Switch the Foxcart ON/OFF breaker to OFF and plug the DC cable into the Aircraft DC
6.
receptacle.
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,
7.
8.
the batteries should be allowed to charge before energizing the Aircraft electrical system.
Perform normal start or maintenance.
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 ships 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.
2.
Oil fan motor and all other moveable parts.

Using compressed air and a dry cloth, clean accumulated dust and grime from unit.
3.
4.
Perform visual inspection and tighten any loose nuts and bolts.
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 (214) 358-4425. Replacement parts may be ordered from the
same number.
1.
2.
Test the wall receptacle for proper voltage.

Using DMM, measure the voltage at the end of the DC Cable. Does the measure-
3.
ment agree with for Foxcart voltmeter?

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.
B.
Plug the AC cable into wall receptacle.

Turn on Foxcart power.
C.
Test the voltage between Terminal A to C and A to E and C to E. All

should be the same voltage. The voltage should also be the same as your
D.
wall voltage.
If step C is incorrect, the problem is between the wall and the input
E.
strapboard.
Turn OFF the Foxcart power.
F.
G.
Remove the AC cable from the wall receptacle.

Using DMM, measure the resistance between the AC plug and the input
H.
strapboard. All readings should be INFINITE.

With the AC plug still removed from the wall receptacle, turn on main
Foxcart circuit breaker. Measure resistance between AC 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
C.
as wires or connections.
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.
G.
Inspect the blue filter capacitors and wiring for leakage or burnt wires.
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
HANDLE HEIGHT
ABOVE GROUND
31.0
BOX DIMENSION
31.5
20.0
BOX DIMENSION
25.5
BOX HEIGHT
21.0
BOX DIMENSION
30.0
OUTSIDE WHEELS DIMENSION
GROUND LEVEL
UNIT WEIGHT ALL MODELS

1200/1600/2000
APPROX. 600 POUNDS
FIGURE 1.
17
OUTPUT
LOAD
NORMAL
SOFT
START
16
18
DC
VOLTAGE
ADJUST
13
14
15
12
11
9
6
DC
VOLTS
DC
AMPHRES
LO
10
HI
AMPMETER RANGE
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
ITEM
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
UTILITY 115 VOLT STRAPPING
COVER PLATE
15 AMP FUSE
INPUT POWER STRAPPING
INPUT POWER STRAPPING PANEL
DESCRIPTION
3448 W. Mockingbird Ln.
Dallas, TX 75235
PHONE: 214/358-4425
FAX: 214/358-1519
foxtronics
incorporated
1
4
FIGURE 2.
TITLE: FOXCART FRONT PANEL COMPONENTS

DRAWING NO: 4000001-007
PAGE: 1 OF 1
REV: B
DRAWN BY: SE
APPROVED BY:
DATE:
10/01/01
230
208
240
2
4
3
1
2
4
1
2
3
1
4
E
REV: B
DRAWN BY: SE
APPROVED BY:
4
E
2
4
3
480V
NOTE: IF INPUT AC POWER IS 380 VAC OR ABOVE AND STEPDOWN TRANSFORMER IS INSTALLED. TERMINALS W, W,
Y AND Z ARE DISCONNECTED.
W
Z
DATE: 10/01/01
PAGE: 1 OF 1
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.
208 TO 250 VAC LINE

15 AMP FUSES
TITLE: FOXCART AC INPUT VOLTAGE STRAPPING

DRAWING NO: 400-0001-003
FOXCART MODEL 1600/2000
X
Dallas, TX 75235
PHONE: 214/358-4425
FAX: 214/358-1519
440V
480V
incorporated
4
E
FOXCART MODEL 1600-C ONLY
foxtronics
1
2
240V
3
F
380V
440V
3
F
1
2
B
4
3
4
2
4
225V
4
E
2
4
2
4
208V
230V
208V
1
2
3
B
4
1
2
4
E
1
2
FOXCART MODEL 1200
FIGURE 3.
23
19
18
17
21
16
20
22
FIGURE 4.
11
14
15
27
26
13
12
7
8
25
24
10
ON/OFF BREAKER
DRAWN BY: SE
APPROVED BY:
DRAWING NO: 400-0001-005
PAGE: 1 OF 1
REV: B
DATE: 10/01/01

Dallas, TX 75235
PHONE: 214/358-4425
FAX: 214/358-1519
DESCRIPTION
TITLE: FOXCART COMPONENT PARTS
incorporated
foxtronics
ITEM
VOLT METER
3
1
STEP SWITCH
LIGHT (GREEN) POWER ON
14/28 VDC SWITCH

LIGHT (RED) REVERSE CURRENT
SOFT START SWITCH
7
6
AC RECEPTICLE
SERVICE PLUG CIRCUIT BREAKER

AMPMETER
TRANSFORMER
10
RIGHT DIODE PLATE ASSEMBLY
13
11
STABILIZING RESISTOR
14
AMMETER SHUNT
SOFT START
15
12
REVERSE DIODES
CAPACITOR (40,000 MF)
16
FAN ASSEMBLY
17
18
CHOKE
(CONDENSER) 2 MF CAPACITOR
20
19
DIODE
LEFT DIODE PLATE ASSEMBLY
MOUNT FAN
23
21
AMPMETER RANGE SWITCH
24
22
INPUT STRAP BOARD
LIGHT (WHITE) 14VDC ON
STEP-DOWN TRANSFORMER
25
26
27
GREEN
WHITE
BLACK
100A
4
5
6
7
15A
4
5
208
230
240
15A
6
7
FAN
230V
X
W
10A
FIGURE 5.
OPTIONAL REVERSE
CURRENT
115V SERVICE
1 K.V.A. MAX
+
-
THIS DRAWING IS APPLICABLE TO ALL 1200 FOXCARTS

WITH -A S/N's AND 1200B SERIES.
.9
CHOKE
GRN
incorporated
foxtronics
APPROVED BY:
DRAWN BY: SE
DATE: OCTOBER 8, 2001

REV: B
PAGE: 1 OF 1
DRAWING NO: 400 0005 002

Dallas, TX 75235
PHONE: 214/358-4425
FAX: 214/358-1519
CORRECT FAN MOTOR WIRING TO BE

COMPATIABLE WITH EITHER 240/480VAC
INPUT
NORMAL
METER RANGE SWITCH
TITLE: 1200 FOXCART w/REVERSE CURRENT DIODE
RED
+
VOLTS
SHUNT
LOW
AMPS
70A FOR 1600

100A FOR 2000
230V
FAN
50 OR 60 Hz
15A
15A
X
W
480
240
230
208
480
240
230
208
T3
T2
T1
480
240
230
208
GREEN
WHITE
BLACK
RED
10A
4 COND
#6 CABLE
OPTIONAL REVERSE CURRENT

DIODES
FIGURE 6.
NOTE:
FOR USE WITH 380VAC INPUT OR ABOVE STEP-DOWN TRANSFORMER IS REQUIRED
115V SERVICE
1 K.V.A. MAX
302UR(xx)X
LEFT SINK
RIGHT SINK
+
40,000 mf
+
GRN
NORMAL
THIS DRAWING IS APPLICABLE TO ALL 1600/2000

FOXCARTS WITH -A S/N's AND 1600B/2000B SERIES.
CHOKE
SOFTSTART
OPTIONAL
SOFTSTART
RED
APPROVED BY:
DRAWN BY: SE
DATE: 10/09/01
W/REVERSE CURRENT DIODE

& SOFTSTART
REV: B
400-0005-018/028
1600/2000 FOXCART

Dallas, TX 75235
PHONE: 214/358-4425
FAX: 214/358-1519
14V TAPS ON M2000

TRANSFORMER ONLY

INPUT
PAGE: 1 OF 1
DRAWING
NO:
TITLE:
incorporated
NORMAL
METER RANGE SWITCH
foxtronics
VOLTS
LOW
AMPS
SHUNT
70A FOR 1600

100A FOR 2000
230V
FAN
50 OR 60 Hz
15A
15A
T2
T3
480
240
230
208
480
240
230
208
T1
10A
4 COND
#6 CABLE
FIGURE 7.
NOTE:
FOR USE WITH 380VAC INPUT
OR ABOVE STEP-DOWN TRANSFORMER
IS REQUIRED
115V SERVICE
1 K.V.A. MAX
302UR(xx)X
LEFT SINK
28V
480
240
230
208
GREEN
WHITE
BLACK
RED
RIGHT SINK
14V
DIODES
40,000 mf
+
GRN
NORMAL

CHOKE
SOFTSTART
RED
WHT
OPTIONAL
SOFTSTART
LOW
AMPS
14V TAPS ON M2000

TRANSFORMER ONLY
incorporated
APPROVED BY:
DRAWN BY: SE
DATE: 10/08/01
W/REVERSE CURRENT DIODE

SOFTSTART & 14/28 SWITCH
REV: B
400-0005-019/029
PAGE: 1 OF 1
DRAWING NO:

Dallas, TX 75235
PHONE: 214/358-4425
FAX: 214/358-1519

INPUT
foxtronics
METER RANGE SWITCH
NORMAL
TITLE: 1600/2000 FOXCART
28V
14V
VOLTS
SHUNT
70A FOR 1600

100A FOR 2000
230V
FAN
50 OR 60 Hz
15A
15A
480
240
230
208
480
240
230
208
T3
T2
T1
480
240
230
208
GREEN
WHITE
BLACK
RED
H3
H2
H4
4 COND
#6 CABLE
X2
X1
10A
302UR(xx)X
LEFT SINK
FIGURE 8.
RIGHT SINK
40,000 mf
OPTIONAL
TRANSFORMER
+
+
GRN
NORMAL

NOTE:
FOR USE WITH 380VAC INPUT OR ABOVE STEP-DOWN
TRANSFORMER IS REQUIRED
115V SERVICE
1 K.V.A. MAX
CHOKE
SOFTSTART
OPTIONAL
SOFTSTART
DIODES
RED
REV: B
APPROVED BY:
PAGE: 1 OF 1
DRAWN BY: SE
DATE: 10/08/01
W/ REV. CURR., SOFTSTART,

STEPDOWN TRANSFORMER

Dallas, TX 75235
PHONE: 214/358-4425
FAX: 214/358-1519
14V TAPS ON M2000

TRANSFORMER ONLY
DRAWING NO: 400-0005-017/027
TITLE: 1600/1200 FOXCART

INPUT
incorporated
NORMAL
METER RANGE SWITCH
foxtronics
VOLTS
LOW
AMPS
SHUNT
GREEN
BLACK
WHITE
RED
GREEN
WHITE
SINGLE PHASE
(REAR VIEW OF CONNECTOR)
L1
L2
HUBBELL 3100P6W WIRE CONNECTIONS
4/3 CABLE (ONLY)
3 PHASE
6/4 CABLE
L1
L2
L3
BLACK
GREEN
BLACK
WHITE
FIGURE 9.
L1
(REAR VIEW OF CONNECTOR)
L2
REV: C
APPROVED BY:
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DATE: 07/30/08

Dallas, TX 75235
PHONE: 214/358-4425
FAX: 214/358-1519
PAGE: 1 OF 1
DRAWING NO: 400-0005-033
TITLE: FOXCART AC CONNECTOR WIRING
incorporated
foxtronics
L3
4/3 CABLE
SINGLE PHASE
HUBBELL 460P7W WIRE CONNECTIONS
114 MM
4 1/2"
3 7/8"
98.4 MM SQ.
FRONT
VIEW
7/32" 5.5 MM DIA.

(4 HOLES)
4 1/2"
114.4 MM SQ.
257.5 MM
10 9/64"
P/N 401-0006-007
HUBBELL 460P7W WALL PLUG
5 7/64"
129.7 MM
4 5/64"
END
VIEW
FIGURE 10.
103.5 MM
1 11/16"
REV: 10/01/01
APPROVED BY:
DRAWN BY: SE
DATE: 10/01/01

Dallas, TX 75235
PHONE: 214/358-4425
FAX: 214/358-1519
PAGE: 1 OF 1
DRAWING NO: 400-0005-034
3 3/32"
88 MM DIA.
42.8 MM
TITLE: HUBBELL 460P7W & 460R7W AC PLUGS
incorporated
foxtronics
P/N 401-0037-000
WALL
BOX
P/N 401-0038-000
HUBBELL 460R7W WALL RECEPTICLE
ASSEMBLY: MODEL 1200 / 60 Hz

COMPONENTS
COMPONENTS
401-0001-012
401-0002-016
401-0003-016
401-0004-016
401-0005-016
401-0006-001
401-0006-006
401-0006-012
401-0007-000
401-0008-001
401-0009-016
401-0009-017
401-0010-016
401-0012-016
401-0015-001
401-0019-016
401-0019-017
401-0020-012
401-0021-012
401-0023-001
401-0023-005
401-0023-013
401-0023-016
401-0023-017
401-0023-018
401-0023-019
401-0023-021
401-0025-016
401-0026-001
401-0026-002
401-0026-003
401-0027-016
401-0041-001
401-0041-002
401-0041-003
401-0052-000
401-0068-001
401-0068-003
401-0068-003
401-0068-006
401-0068-007
401-0071-002
402-0045-001
404-1600-010
404-1600-012
404-1600-014
404-1600-016
APPENDIX A-1
DESCRIPTION
UNITS REQ. ASSEMBLY
DESCRIPTION
UNITS REQ. ASSEMBLY
412-7-T2 TAP SWITCH
1.0
NO
3M578 FAN MOTOR
1.0
NO
2C842-8 / 12 BLADE
1.0
NO
TRIPLET / DC VOLT METER 0-40VDC
1.0
NO
DC AMP METER: DUAL 0-800; 0-1600
1.0
NO
RED-DOTCVR CCD DCI-78440135000
1.0
NO
CR15-1 IVORY DUPLEX; HUBBELL
1.0
NO
AC PLUG, 3100P6W
1.0
NO
AN3161-10/10A-CB
1.0
NO
219-3-1-62F-89-100 480V/BKR
1.0
NO
502-3241-102 LT/ASY
1.0
NO
LAMP. TYPE 313
1.0
NO
LENSE GREEN 320112300
1.0
NO
600A/50mv SHUNT; HA600-50
1.0
NO
75 OHM, 5W, RESIST. PW5-75
1.0
NO
CGS4030040X4C/40,000MF 40V
5.0
NO
CLAMP VR12B (3)
5.0
NO
CHOKE; MOD 1200
1.0
NO
TRANSFORMER/1200
1.0
NO
FR/PL, PLATE 8X 8
1.0
NO
FRONT PNL (NEW-DWG)
1.0
NO
CHASSIS FRAME
1.0
NO
COVER
1.0
NO
BRACKET, FAN MT
1.0
NO
PLATE RE-ENFORCE
2.0
NO
HANDLE, FOXC
2.0
NO
REAR PANEL
1.0
NO
CASTER TP505001SR-B SR = SWBRAKE
2.0
NO
PILLOW BLK 2X530 x
2.0
NO
AXLE x 29 3/8
1.0
NO
SHAFT COLLAR 2 x 570 x
2.0
NO
TIRE, 4.10/850-4PN, BEARING
2.0
NO
DIAL KNOB # 5152A
1.0
NO
VOLT-ADJ DECAL
1.0
NO
5003/1-7/DIAL/IND/PLATE
1.0
NO
CABLE ASSEMBLY/DC, 15FT/W/PLUG
1.0
NO
DECAL, FOXCART S/N MODEL, 1200
1.0
NO
DECAL, FOXCART LOGO
2.0
NO
DECAL, 115V
1.0
NO
DECAL, CAUTION
1.0
NO
DECAL, HI / LO (AMP)
1.0
NO
SWITCH, TOGGLE #93-4001SPSTON/MO
1.0
NO
4/3 SEOW AC CABLE
50.0
NO
LOAD RESISTOR
2.0
YES
STRAPBOARD MODEL 1200
1.0
YES
LEFT DIODE PLATE 1200
1.0
YES
RIGHT DIODE PLATE 1200
1.0
YES

COMPONENTS
COMPONENTS
401-0001-016
401-0002-016
401-0003-016
401-0004-016
401-0005-016
401-0006-001
401-0006-006
401-0006-007
401-0007-000
401-0008-016
401-0009-016
401-0009-017
401-0010-016
401-0012-016
401-0015-001
401-0019-016
401-0019-017
401-0020-016
401-0021-016
401-0023-001
401-0023-005
401-0023-013
401-0023-016
401-0023-017
401-0023-018
401-0023-019
401-0023-021
401-0025-016
401-0026-001
401-0026-002
401-0026-003
401-0027-016
401-0041-001
401-0041-002
401-0041-003
401-0052-000
401-0068-000
401-0068-003
401-0068-005
401-0068-006
401-0068-007
401-0071-002
402-0045-002
404-1600-003
404-1600-006
404-1600-007
404-1600-010
APPENDIX A-2
DESCRIPTION
UNITS REQ. ASSEMBLY
DESCRIPTION
UNITS REQ. ASSEMBLY
412-7-T2 TAP SWITCH
1.0
NO
3M578 FAN MOTOR
1.0
NO
2C842-8 / 12 BLADE
1.0
NO
1.0
NO
1.0
NO
1.0
NO
1.0
NO
AC PLUG, 460P7W
1.0
NO
AN3161-10/10A-CB
1.0
NO
70ABK/480V 219-3-1-65F-8-9-70
1.0
NO
502-3241-102 LT/ASY
1.0
NO
LAMP. TYPE 313
1.0
NO
1.0
NO
1.0
NO
1.0
NO
CGS4030040X4C/40,000MF 40V
2.0
NO
CLAMP VR12B (3)
2.0
NO
CHOKE; MOD 1600
1.0
NO
TRANSFORMER/1600 50/60Hz
1.0
NO
FR/PL, PLATE 8X 8
1.0
NO
FRONT PNL (NEW-DWG)
1.0
NO
CHASSIS FRAME
1.0
NO
COVER
1.0
NO
BRACKET, FAN MT
1.0
NO
PLATE RE-ENFORCE
2.0
NO
HANDLE, FOXC
2.0
NO
REAR PANEL
1.0
NO
2.0
NO
PILLOW BLK 2X530 x
2.0
NO
AXLE x 29 3/8
1.0
NO
2.0
NO
2.0
NO
DIAL KNOB # 5152A
1.0
NO
VOLT-ADJ DECAL
1.0
NO
1.0
NO
1.0
NO
1.0
NO
DECAL, FOXCART LOGO
2.0
NO
DECAL, 115V
1.0
NO
DECAL, CAUTION
1.0
NO
1.0
NO
1.0
NO
6/4 SEOW AC CABLE
50.0
NO
1.0
YES
1.0
YES
1.0
YES
LOAD RESISTOR
1.0
YES

COMPONENTS
COMPONENTS
401-0001-016
401-0003-016
401-0002-016
401-0004-016
401-0005-020
401-0006-001
401-0006-006
401-0006-007
401-0007-000
401-0008-001
401-0009-016
401-0009-017
401-0010-016
401-0013-016
401-0015-001
401-0019-016
401-0019-017
401-0020-020
401-0021-020
401-0023-001
401-0023-005
401-0023-013
401-0023-016
401-0023-017
401-0023-018
401-0023-019
401-0023-021
401-0025-016
401-0026-001
401-0026-002
401-0026-003
401-0027-016
401-0041-001
401-0041-002
401-0041-003
401-0052-000
401-0068-002
401-0068-003
401-0068-005
401-0068-006
401-0068-007
401-0071-002
402-0045-002
404-1600-003
404-1600-010
404-1600-018
404-1600-020
APPENDIX A-3
DESCRIPTION
UNITS REQ.
ASSEMBLY
DESCRIPTION
UNITS REQ. ASSEMBLY
412-7-T2 TAP SWITCH
1.0
NO
2C842-8 / 12 BLADE
1.0
NO
3M458 FAN MOTOR 50Hz
1.0
NO
1.0
NO
1.0
NO
1.0
NO
1.0
NO
AC PLUG, 460P7W
1.0
NO
AN3161-10/10A-CB
1.0
NO
219-3-1-62F-89-100 480V/BKR
1.0
NO
502-3241-102 LT/ASY
1.0
NO
LAMP. TYPE 313
1.0
NO
1.0
NO
1.0
NO
1.0
NO
CGS4030040X4C/40,000MF 40V
2.0
NO
CLAMP VR12B (3)
2.0
NO
CHOKE; MOD 2000
1.0
NO
TRANSFORMER/2000
1.0
NO
FR/PL, PLATE 8X 8
1.0
NO
FRONT PNL (NEW-DWG)
1.0
NO
CHASSIS FRAME
1.0
NO
COVER
1.0
NO
BRACKET, FAN MT
1.0
NO
PLATE RE-ENFORCE
2.0
NO
HANDLE, FOXC
2.0
NO
REAR PANEL
1.0
NO
2.0
NO
PILLOW BLK 2X530 x
2.0
NO
AXLE x 29 3/8
1.0
NO
2.0
NO
2.0
NO
DIAL KNOB # 5152A
1.0
NO
VOLT-ADJ DECAL
1.0
NO
1.0
NO
1.0
NO
1.0
NO
DECAL, FOXCART LOGO
2.0
NO
DECAL, 115V
1.0
NO
DECAL, CAUTION
1.0
NO
1.0
NO
1.0
NO
6/4 SEOW AC CABLE
50.0
NO
1.0
YES
LOAD RESISTOR
1.0
YES
1.0
YES
1.0
YES
ASSEMBLY: 50 Hz OPTION (Prior to 3-1-07)

COMPONENTS
COMPONENTS
401-0003-018
401-0003-019
401-0003-020
DESCRIPTION
DESCRIPTION
3M459 FAN MOTOR 50Hz
3M492 MOUNT
SPLIT RING ADAPTOR
APPENDIX A-4
UNITS REQ.
ASSEMBLY
UNITS REQ. ASSEMBLY
1.0
NO
1.0
NO
1.0
NO
UNITS REQ.
ASSEMBLY
UNITS REQ. ASSEMBLY
1.0
NO
2.0
NO
3.0
NO
ASSEMBLY: 50 Hz OPTION (After 3-1-07)

COMPONENTS
COMPONENTS
401-0002-017
401-0023-060
401-0090-000
DESCRIPTION
DESCRIPTION
DC FAN
FAN BRACKET MOUNT
STAND OFF
ASSEMBLY: SOFTSTART OPTION

COMPONENTS
COMPONENTS
401-0045-003
401-0068-008
401-0071-004
401-1023-000
402-1022-000
404-0004-000
DESCRIPTION
UNITS REQ.
ASSEMBLY
DESCRIPTION
UNITS REQ. ASSEMBLY
CABLE, (DC) WELDING TYPE 2/0
5.0
NO
DECAL, SOFT START
1.0
NO
TOG/SWITCH C/H #8792K3 SOFT-START
1.0
NO
YELLOW 2/0 322090 (2J1871)
2.0
NO
YELLOW 2/0 322089 (ZZ251869)
6.0
NO
SOFT START GRID
1.0
NO
ASSEMBLY: REVERSE CURRENT OPTION

COMPONENTS
COMPONENTS
401-0009-016
401-0009-017
401-0010-017
401-0015-001
401-0016-001
402-0046-005
402-1014-000
402-1020-002
DESCRIPTION
DESCRIPTION
502-3241-102 LT/ASY
LAMP TYPE 313
LENSE, RED #25F-1576
75 OHM, 5W, RESISTOR PW5-75
302U10A POS DIODE; REV/CUR
18 GA WIRE
BLUE #10 36160
RED 3/8 31897
UNITS REQ.
ASSEMBLY
UNITS REQ. ASSEMBLY
2.0
NO
2.0
NO
1.0
NO
2.0
NO
3.0
NO
5.0
NO
2.0
NO
1.0
NO
APPENDIX B
B1
Chart for 1200
B2
Chart for 1600
B3
Chart for 2000
DC VOLTS OUTPUT
10
15
20
25
30
35
15
100
300
400
500
46
600
700
800
1000
1100
70
DC AMPERES OUT
900
90
1200
1300
100
1400
1500
AC LINE INPUT AMPERES PER LEG at 245 VOLTS USING 50ft 4 COND.+0 CABLE
200
TYPICAL MODEL 1200 OUTPUT CURVE USING 240V 60 Hz
110
1600
1700
1800
1900
145
2000
DC VOLTS OUTPUT
10
15
20
25
30
35
15
100
300
400
500
46
600
700
800
1000
1100
70
DC AMPERES OUT
900
90
1200
1300
100
1400
1500
200

for 50 Hz de-rate 15%
110
1600
1700
1800
1900
145
2000
DC VOLTS OUTPUT
10
15
20
25
30
35
100
15
300
400
500
46
600
700
800
1000
1100
70
DC AMPERES OUT
900
90
1200
1300
100
1400
1500
200

for 50 Hz de-rate 15%
110
1600
1700
1800
1900
145
2000

Foxcart MKII Manual

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FOXCART MARK II

OPERATION AND SERVICE MANUAL

UNIT WEIGHT - ALL MODELS

THE POWER CART WITH MUSCLE

MADE IN THE USA

3448 WEST MOCKINGBIRD LANE

Revised: August, 2008

PHONE (214) 358-4425

6. PREPARATION FOR USE

10. FIGURES / DIAGRAMS

OTHER VOLTAGES AVAILABLE UPON REQUEST.

OTHER VOLTAGES AVAILABLE UPON REQUEST.

EXTRA LENGTH OF AC CABLE

EXTRA LENGTH OF DC CABLE

Lengths over 25 not recommended.

Limits Starting Current to 1100 AMPS to protect

Extra protection from rain and snow

REVERSE CURRENT DIODES

Prevents aircraft batteries from draining into the

WALL BOX RECEPTACLE KIT

Wall plug to match cable plug

EXTRA SIZE WHEELS

For rough terrain and snow

14/28 VDC SWITCHING KIT

Used for starting 14 or 28-volt aircraft.

115 VAC UTILITY OUTLET

Standard on units operating from 200-250 VAC

WITH TERRAIN WHEELS:

PREPARATION FOR USE

WHEN THE FOXCART IS PLUGGED INTO THE AC OUTLET, ALL OF THE

BEFORE RE-STRAPPING, DISCONNECT THE AC CABLE FROM THE POWER

TERMINALS X AND Y WILL BE HIGH VOLTAGE.

Plug the Foxcart Input Power Cable into the AC Outlet.

ter to the desired voltage.

Oil fan motor and all other moveable parts.

Test the wall receptacle for proper voltage.

ment agree with for Foxcart voltmeter?

Plug the AC cable into wall receptacle.

Test the voltage between Terminal A to C and A to E and C to E. All

Remove the AC cable from the wall receptacle.

strapboard. All readings should be INFINITE.

Remove top cover.

FRONT PANEL COMPONENTS

MODEL 1200B w/REVERSE CURRENT

MODEL 1600B/2000B w/REVERSE CURRENT &

MODEL 1600B/2000B w/14/28VDC OPTION

MODEL 1600B/2000B w/STEPDOWN

AC CONNECTOR WIRE HOOK-UP

460P7W HUBBELL PLUG DIMENTIONS

UNIT WEIGHT ALL MODELS

POWER SWITCH & BREAKER

TITLE: FOXCART FRONT PANEL COMPONENTS

UTILITY PLUG SET-UP

208 TO 250 VAC LINE

TITLE: FOXCART AC INPUT VOLTAGE STRAPPING

FOXCART MODEL 1600/2000

FOXCART MODEL 1600-C ONLY

FOXCART MODEL 1200

DRAWING NO: 400-0001-005

3448 W. Mockingbird Ln.

TITLE: FOXCART COMPONENT PARTS

14/28 VDC SWITCH

SOFT START SWITCH