Home

Pack-Mule-Manual-PC

1. cc CE OCC 6 7 Uc REUS 7 7 OEC Ecc 7 INDUS TRY STANDARDS M 8 OPERATING INSTRUCTION p 12 CTS CRIS TM 12 0 er 12 Sero M 12 Vehicle Controls Meters i acre ass 12 DIVNO Cm 17 TOWIDO ceto E Ml V EAD DIM MM 17 Ger IAS RETE T 17 a Tm 17 TO T mmm 17 Startup Checklist for Industrial heme hene nnn nnns sens sn sn enses 18 NEATNIDEBRIAINCEINSTR OGITOBNS Do etie etie Do ec etd ce Dados etie toe icti 19 Schede o eut o 19 oen t E _ Gaal gt 20 TNS Sun hot 20 Battery Sale sud ura rod To
2. 20 Saec ET 20 mie elec s Et 21 Ballery 21 CIO AnING 21 Balt Replacement EE 21 ENDO VENICE 22 HR DUM eed THE TI 22 Brako Me m cr EE 23 co ccm 24 eee sa 25 ODE EE 25 Change RT TII 26 EE See ee eee 28 3 Owner s Manual and Service Guide PC amp PCT Series __ _ _ ___ eee 28 BD 33 Speed Gonttol Pedal E ludo a ona M 33 I PH 33 ME ee casters ee 35 Parts EISt Available OPIONS EET T 35 COMPONENTS 36 Parts List Front Wheel Steer a 36 Tiansaxo Exploded 37 AS
3. MARO M DIDA ME LAM E 38 Transaxle Troubleshooting c EE 39 PG ale 0 16 g eR A La CL M LOL d E LAM E 41 Owner s Manual and Service Guide PCT Series 4 INTRODUCTION Thank you for choosing a Pack Mule Industrial Electric Vehicle proudly built by Wesley International in the USA At Wesley International we are committed to providing you the best quality product backed by exceptional customer service This owner s manual and service guide is provided to help you get the most out of your new vehicle for many years to come RECORD YOUR PRODUCT INFORMATION Model Serial Purchase Date REGISTER YOUR PRODUCT PRODUCT REGISTRATION IS REQUIRED FOR WARRANTY COVERAGE Registration is easy Simply go to http www packmule com support warranty and complete the online form and click submit That s it Then you will be entitled to free parts for any defective items as outlined in our warranty document IF YOU NEED HELP You will find many answers to common problems within this manual or online at www packmule com If you do not find what you need we are always ready and willing to help Just email us at info wesleyintl com or call 800 241 2869 or 404 292 7441 Wesley International 3680 Chestnut Street ocottdale GA 30079 Phone 404 292 7441 Toll Free 800 241 2869 Fax 404 292 8469 info wesleyint
4. MULE INDUSTRIAL ELECTRIC VEHICLE PCT 3510 TOW VEHICLE Sy An 4 3 _ Sf 5 m x ra OWNER S MANUAL AND SERVICE GUIDE PCT SERIES Nov 2013 Owner s Manual and Service Guide PC amp PCT Series FOREWARD UPON RECEIPT OF VEHICLE EQUIPMENT Please visually inspect the vehicle for any damage that may have occurred during shipping and have it noted on the carrier s bill immediately Be sure to specify the nature of the damage This manual is a VERY IMPORTANT tool Please keep it with the vehicle equipment at all times The purpose of this manual is to provide owner users lessors and or lessees with the operating instructions and precautions for the safe and proper operation of the vehicle or equipment It is the owner user lessor or lessees responsibility to ensure that the vehicle equipment is being used in accordance with its designed intended use Please read this ENTIRE manual to familiarize yourself with the safe operation of this vehicle equipment Pay particular attention to anything labeled CAUTION NOTE OR WARNING Due to continuous product improvements changes or updates may be made to this Manual making it subject to change without notice For the most up to date version of the manual please go to our website http www packmule com support product manuals OR call Wesley International at 1 800 241 2869 The Pack Mule Division of Wesley International reserves the
5. selected l Emergency reverse wire ar check wire l Improper sequence af KSI interlock and thracide inputs 4 2 Misadjusted throne par 3 Sequencing delay tao short 3 Wrong HPD throttle selected 5 par 1 maintenance timer expired 1 diable timer expired 1 Thrattle pot wire open ar shorted Ba 2 Wrong ood per selected Xefecrive pot 1 Main cantactar coil shared 3 winding sha med 3 resistance too low Main contactor stuck closed 1 Main driver shorted windi ng connecrian 2 winding open 1 bhin contactor apen L Main contactor missi ng 3 input wire apen ar shorted Check wiring and cycle KSI Check wiring and cycle KSI KSL If problem persists replace cantraller KSL If problem persists replace cantraller Check wiring cycle KSL If problem R bis replace Follow proper sequence adjust throttle if necessary adjust program parameters if necessary When Throrde Wiper High amp valid range Reapply emergency reverse ar ode lack Follow proper sequence throttle if necessary programmable parameters if necessary When Th
6. Features include e Attractive easy to read 8 character dot matrix Liquid Crystal Display 6 LEDs five green to indicate battery state of charge and one red to indicate that fault has occurred Displays hours of use battery state of charge and messages from the FIGURE 29 Curtis motor controller Molded in rear Molex style connector provides a low cost rugged and reliable installation Front sealed IP65 for use in harsh environments The BDI in 48 volt DC vehicles will display battery state of charge and operating Traction hours only Figure 30 CURTIS FIGURE 30 33 Speed Control Pedal The speed control pedal Figure 31 is a rugged assembly with IP66 throttle sensor protection for reliable use in harsh industrial environments There are no user serviceable parts in the speed control pedal No attempt should be made to open repair or otherwise modify the assembly Doing so may damage the assembly and will void the warranty FP LCV FIGURE 31 SOLENOID The Pack Mule is provided with a SPNO DC Power Contactor This unit is sealed and is water resistant The coil voltage is matched to your particular vehicle operating voltage i e 36V or 48V The AC option uses 24V coil regardless of vehicle system voltage Figure 32 FiGURE 32 Owner s Manual and Service Guide PC PCT Series COMPONENTS ELECTRICAL WIRING DIAGRAM HIL
7. FiGURE 13 Back Up Alarm Optional Optionally a back up may be installed on the vehicle The back up alarm Figure 14 only sounds when the directional switch is placed in the reverse position FIGURE 14 Foot Presence Switch Optional The foot presence switch if present Figure 15 is located on the left side of the floor board This is an added safety feature which may be used alone or in combination with the seat presence sensor switch to prevent the vehicle from operating unless this foot switch is first depressed The operator must use their left foot to depress the foot presence switch before the vehicle will move and should the operators foot leave the foot presence switch during while the vehicle is moving the motor will disengage and the vehicle will slow to a stop Owner s Manual and Service Guide PC PCT Series FIGURE 15 Seat Presence Sensor Switch The presence sensor switch is located under the seat Figure 16 and is designed to prevent operation of the vehicle unless a person is sitting down on the seat If the driver stands up or falls off the seat while the vehicle is in motion the presence sensor switch will disable the vehicle allowing it to come to a stop FIGURE 16 16 OPERATING INSTRUCTIONS DRIVING Follow these steps to operate your Pack Mule vehicle 1 Disconnect the battery charger Unplug the battery charger from the 110V wall plug vehicle will not operate when plugg
8. PROBLEM DIAGNOSIS Most drive axle problems fall into the categories of noise vibration leaks and failure to transmit power Problem diagnosis normally begins with the customer s complaint which should include an exact description of the type of noise or vibration and when it occurs This is followed up by a road test over various types of road surfaces through the speeds where the complaint occurs It should be remembered that some sounds will appear to come from locations other than the real source of the problem Sounds in the drive shaft exhaust system and body floor pan can do this making it more difficult to locate the problem source Condition Probable Cause Noise in all driving modes Road and tires wheel bearings Noise changes with type of road surface Road and tires Noise louder on turns Differential pinion and side gears axle wheel bearings Noise in one or more driving modes Ring and pinion gears Clunk on change of speed or direction of power flow Worn differential shaft or thrust washers worn U joints Vibration Damaged drive shaft missing drive shaft balance weight worn or out of balance wheels loose wheel lug nuts worn U joints loose spring U bolts loose broken spring damaged axle shaft bearings loose pinion gear nut excessive pinion yoke run out bent axle shaft Differential gears scored Insufficient lubrication improper grade of lubricant lubricant contamination excessive spinning of wheels Loss
9. 35 or about 1 2 the forward speed Controller Maintenance There are no user serviceable parts in the Curtis controller No attempt should be made to open repair or otherwise modify the controller Doing so may damage the controller and will void the warranty It is recommended that the controller be kept clean and dry and that its fault history file be checked and cleared periodically Periodically cleaning the controller exterior will help protect it against corrosion and possible electrical control problems created by dirt grime and chemicals that are part of the operating environment and that normally exist in battery powered systems Use the following cleaning procedure for routine maintenance 1 Remove power by disconnecting the battery 2 Discharge the capacitors in the controller by connecting a load such as a contactor coil or a horn across the controller s and B terminals 3 Remove any dirt or corrosion from the connector areas The controller should be wiped clean with a moist rag Dry it before reconnecting the battery The controller should not be subjected to pressured water flow from either a standard hose or a power washer 4 Make sure the connections are tight but do not over tighten them Owner s Manual and Service Guide PC amp PCT Series COMPONENTS ELECTRICAL Controller Wiring Typical Controller wiring configuration of PC series vehicles The interlock switch is a seat switch or foot swit
10. automobile Depressing the pedal starts the motor Releasing the pedal stops the motor Reverse speed is half of forward speed FIGURE 9 FIGURE 10 Brake Pedal The brake pedal Figure 11 is located to the left of the accelerator pedal and is the smaller of the two Applying pressure on the brake pedal will slow the vehicle down in addition to the motor braking If driving down an incline the brake pedal should be used to control the speed FIGURE 11 Parking Brake Optional The parking brake lever is lifted up to place the parking brake on as shown in Figure 12 and it also disables the motor controller in the process To release simply push the lever forward and into the down position as shown in Figure 12 The tension of the parking brake can be adjusted by simply twisting the parking brake handle while the parking brake is in the forward and down dis engaged position Turning the handle counter clockwise tightens the tension applied as shown in Figure 12 Turning the handle clockwise loosens the tension Be careful not to over tighten or the life of the brake cable may be shortened BRAKE ENGAGED POSITION FIGURE 12 Owner s Manual and Service Guide PC amp PCT Series OPERATING INSTRUCTIONS Horn and Horn button The horn button is located at the top of the right handlebar It is operated by the right hand The horn Figure 13 will not sound when the key or on off switch is in the off position
11. be operated at a speed that will permit it to be brought to a stop in a safe manner 7 3 2 9 Make starts stops turns or direction reversals in a smooth manner so as not to shift the load endanger passengers or lose control of the carrier 7 3 2 10 Do not operate carrier in a dangerous manner 7 3 2 11 Slow down when approaching or on wet or slippery surfaces 7 3 2 12 Do not drive carrier onto any elevator unless specifically authorized to do so Approach elevators slowly and then enter squarely after the elevator car is properly leveled Once on the elevator neutralize the controls shut off power and set parking brakes It is advisable that all other personnel leave the elevator before a carrier is allowed to enter or exit 7 3 213 Avoid running over loose objects potholes and bumps 7 3 2 14 Reduce carrier speed to negotiate turns 7 3 2 15 Avoid any action verbal or physical by an operator or passenger which could cause the operator to be distracted 7 3 3 Loading 7 3 3 1 Refer to operators manual for loading instruction 7 3 3 2 Handle only stable and safely arranged loads When handling off center loads which cannot be centered operate with extra caution 7 3 3 3 Handle only loads within the capacity of each cargo area of the carrier as specified by the manufacturer 7 3 3 4 Avoid material loads exceeding the physical dimensions of the carrier or as specified by the carrier manufacturer 10
12. filtration system Electrolyte level should be 72 13 mm above the plates in each cell This level will leave about 3 8 6 10 mm of space between the electrolyte and the vent tube The level of the electrolyte is important Too low and the plates will be exposed to air ruining them beyond repair Too high and the electrolyte will be forced out of the battery due to gassing and the increased volume of the electrolyte resulting from the charging cycle BATTERY WATERING SYSTEM Wesley International offers a battery watering system Figure 19 as an option on all its vehicles This system is a fast accurate and safe means of maintaining precise electrolyte levels in the batteries FIGURE 19 21 To use the watering system simply fill the gravity feed container with a clean water source Connect the blue connector at the end of the container flow tubing to the blue connector at the end of the battery watering system attached to the batteries Elevate the gravity feed container at least 3 feet 1 m to properly fill the batteries CLEANING BATTERIES It is important to first neutralize any acid deposits with a solution of sodium bicarbonate baking soda and water Spray the top and sides of the batteries with this solution Use 4 60 mL of sodium bicarbonate mixed with 1 gallons 6 L of water Let the solution sit for at least three minutes Rinse entire area with low pressure clear water BATTERY R
13. low overhangs with caution Be sure there is enough clearance for the operator s head and the highest point of the vehicle or any attached accessories e Never abruptly change direction e Always drive directly up an incline never across e Never exceed the designated passenger load or towing capacity On grades it is possible for vehicles to coast at greater than normal speeds encountered on a flat surface To prevent loss of vehicle control and possible serious injury soeeds should be limited to no more than maximum speed on level ground Owner s Manual and Service Guide PC amp PCT Series 6 SAFETY INFORMATION Good common sense and prudent driving practices do more to prevent accidents and injuries than all of the warnings and instructions combined Wesley International strongly suggests that the owner operator read this entire manual paying particular attention to the CAUTIONS and WARNINGS contained therein Loading and Unloading Follow these guidelines when loading and unloading cargo from the vehicle or trailers Turn the vehicle off while loading Do not exceed the maximum passenger or cargo load capacity Carefully and evenly position all loads Secure cargo so that nothing can easily fall off of the vehicle or trailer Be extremely careful carrying loads that extend beyond the vehicle s deck TOWING Follow these guidelines when towing Turn the vehicle off when connecting equipment that will be towed Always use a pr
14. of Supervisor Mode CE can be pressed several times to make sure you are completely clear and ready to enter the next mode 4 Log onto the User Mode Press 0 1 1 2 3 4 ENTER The switch will close and the Green LED will flash at a slow rate 5 Change User PIN First decide on a new PIN In this example e use 5 4 3 2 1 Press 1 ENTER This puts you in the Change User PIN Menu Note that the switch will open when you go into this menu Note The User has 1 minute after logging on the User Mode to use menu 1 before the menu function is locked out until the next User log on Press 5432 1 ENTER again press 5 4 3 2 1 ENTER The switch will indicate that the new PIN has been accepted 6 Use the new PIN to close the switch Press 0154 32 1 ENTER The switch will close Press ENTER to open the switch and go out of User Mode Since this is an example you may want to set the PIN for User location 01 back to the 1234 default 7 Log back onto the Supervisor Mode to change the Supervisor PIN Press 00123 4 ENTER Press 1 ENTER to go into the Change Supervisor PIN Menu The red LED will flash once Now just you did in the User Mode put the new PIN in twice and enter each time Example Press 5 4 3 2 1 ENTER again 5 4 3 2 1 ENTER The switch will give an indication that the PIN was changed Owner s Manual and Service Guide PC amp PCT Series OPERATING INSTRUCTIONS 8 Go out of Menu 1 Press CE Press CE agai
15. personal injury or death keep all smoking materials open flame or sparks away the batteries Hydrogen gas forms when charging batteries Do NOT charge batteries without adequate ventilation Seat must be raised when charging batteries Only a 4 concentration of hydrogen gas is explosive Be sure the key switch or on off switch is in the OFF position and all electrical accessories are off before starting work on the vehicle Open the vehicle s circuit switch Figure 18 before starting work on the vehicle The electrolyte in a lead acid battery is an acid solution which can cause severe burns to the skin and eyes Treat all spills to the body and eyes with extended flushing with clear water Then contact a physician immediately Electrolyte spills will corrode the vehicle s structural frame and body if not properly treated immediately In the event of a spill wear proper protective clothing gloves and eye wear Thoroughly clean all affected areas with a neutralizing solution of cup 60 mL sodium bicarbonate baking soda dissolved in 1 1 gallons 6 L of water It is highly recommended that insulated wrenches be used when working on our electric vehicles Alternatively wrap wrenches with vinyl tape to prevent the possibility of a dropped wrench onto batteries terminals which can short the battery which could result in an explosion and severe personal injury or death BATTERY CARE 1 Place battery into service
16. premises and as conditions warrant identify areas where carriers should not be operated and to identify possible hazards such as the following examples a Steep Grade In areas where steep grades exist carrier operation should be restricted to the designated vehicle s pathways where possible and shall be identified with a suitable warning giving the following information Warning steep grade Wet Areas Wet areas could cause a carrier to lose traction and could affect steering stability and braking c Sharp Turns Blind Spots Bridge Approaches Sharp turns blind spots bridge approaches and other potentially hazardous areas shall be identified with a suitable warning to the operator of the nature of the hazard and stating the proper precautions to be taken to avoid the hazard d Loose Terrain Loose terrain could cause a carrier to lose traction and could affect steering stability and braking 6 2 Operation Experience has shown that carriers which comply with the provisions stated in paragraphs 9 4 9 5 and 9 6 are stable when properly operated and when operated in accordance with specific safety rules and practices established to meet actual operating terrain and conditions However improper operation faulty maintenance or poor housekeeping may contribute to a condition of instability and defeat the purpose of the standard Some of the conditions which may affect Stability are failure of the u
17. right to incorporate engineering and design changes to products in this manual without any obligation to include these changes on any units vehicles already purchased or leased The Pack Mule Division and or Wesley International accepts no liability in connection with any errors or omissions in this Manual and SPECIFICALLY DISCLAIMS any liability for any incidental and consequential damages arising from the use of the information in this Manual The use of non OEM Original Equipment Manufacturer parts may void the warranty the batteries may void your warranty The PCT tow vehicle is a Class VI Industrial Truck Only operators trained per OSHA requirements shall operate this vehicle NOIES CAUTIONS AND WARNINGS Throughout this guide NOTE CAUTION and WARNING will be used Please observe these notes cautions and warnings A NOTE indicates a condition that should be observed CAUTION A CAUTION indicates a condition that may result in damage to the vehicle N WARNING A WARNING indicates a hazardous condition that could result in severe injury or death Owner s Manual and Service Guide PC amp PCT Series 2 TABLE OF CONTENTS LN een on CT 5 MINOR IIA Cc 6 men EEE E Eee 6 Eat ENDE EN m 6
18. to operate the carrier Operators shall be qualified as to visual auditory physical and mental ability to safely operate the equipment according to Section 7 all other applicable parts of this Standard and the operators manual 7 2 Personnel and Burden Carrier Operators Training 7 2 1 The user shall conduct an operators training program 7 2 2 Successful completion of the operators training program by the operator shall be required before operation of the carrier The program shall be presented in its entirely to all new operators and not condensed for those claiming previous experience 7 2 3 The user shall include as a minimum in the operators training program the following Instructional material provided by the manufacturer including the operators manual b Emphasis on safety of passengers material loads carrier operator and other person s c General safety rules contained within this Standard and the additional specific rules determined by the user in accordance with this Standard and why they were formulated d Introduction of equipment control locations and functions and explanation of how they work when used properly and when used improperly and surface conditions grade and other conditions of the environment which could affect carrier operation e Operator competency evaluations Owner s Manual and Service Guide PC amp PCT Series INDUSTRY STANDARDS 7 3 Personnel and Burden C
19. which has molded recesses in the tire that create a smoother ride similar to a pneumatic tire Replacing Front Tires Wheels To remove and repair the front tires and or wheels complete the following steps 1 Remove the axle nut retaining clip 2 Lift the front of the vehicle as explained in the Lifting the Vehicle Section 3 Loosen the axle nuts and remove the entire wheel hub and axle assembly from front fork 4 Remove the lug nuts and remove the wheel from the axle assembly 5 Reinstall the repaired or replacement tire by reversing the above sequence Tighten to 70 to 80 ft lbs 95 to 108 Nm torque Owner s Manual and Service Guide PC amp PCT Series Replacing Rear Tires Wheels To remove and repair the rear tires and or wheels complete the following steps 1 Loosen the lug nuts on the wheel 2 Lift the rear of the vehicle as explained in the Lifting the Vehicle Section 3 Remove the lug nuts and remove the wheel from the transaxle 4 Reinstall the repaired or replacement tire by reversing the above sequence Tighten to 70 to 80 ft Ibs 95 to 108 Nm torque 24 COMPONENTS ELECTRICAL BASIC ELECTRICAL COMPONENTS Your Pack Mule electric vehicle is purposely designed around the Keep it Simple principal Our philosophy at Wesley International is to engineer products with only the critical components necessary to meet the demanding industrial environment cutting out any unnecessary bells
20. EPLACEMENT Remove battery hold downs and cables Lift out batteries with a safety rated lifting device 1 INPUT CONNECTION 48 VOLT SYSTEM WIRING PROPOSITION 65 WARNING gt Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm gt Batteries also contain other chemicals known to the State of California to cause cancer gt Wash hands after handling Owner s Manual and Service Guide PC amp PCT Series MAINTENANCE INSTRUCTIONS LIFTING THE VEHICLE NWARNING To prevent possible injury or death resulting from a vehicle falling from a jack be sure the vehicle is on a firm and level surface Never beneath a vehicle while it is supported by a crane or jack Use jack stands and test the stability of the vehicle Always place chocks in front and behind the wheels not being raised Use extreme care when lifting due to the 3 point wheel design which 15 extremely unstable when lifting especially lifting the rear The vehicle should only be lifted high enough to remove the front axle or rear wheels Position jacks and jack stands only on the areas indicated Figure 20 FiGURE 20 Lifting the front To remove a front wheel or axle First chock the front and rear of the rear tires Loosen the front wheel hardware Position the ja
21. EV E027 Charger Cord EV E026 Onboard Battery Charger 48 volt EV E801 48 Motor DC EV D040 S Motor AC EV E185 Speed Control Pedal Assembly EV E Directional Switch 3 position Toggle EV E035 Seat Presence Sensor Switch EV E528 35 PARTS LIST AVAILABLE OPTIONS Part Number Perma Key Switch EV E194PK On Off Switch 017 Programmable Code Security Switch EV E901 Headlight Taillight Brake light 48 volt EV E191 48 Flashing Safety Beacon Amber EV E183 Flashing Safety Beacon Red EV E182R Back up Alarm EV E159A Proximity Alarm EV E149 Hitch Spring Loaded Clevis 1 pin EV F130H Hitch Spring Loaded Clevis 5 8 pin EV F178H Hitch Pin EV F134P Hitch Pintle EV F092 Hitch Eye 2 3 8 EV F132 Hitch Auto Coupling EV F133H Hitch 3 Tier Assembly with Pin EV F134 Owner s Manual and Service Guide PC amp PCT Series COMPONENTS MECHANICAL PARTS LIST FRONT WHEEL STEER ASSEMBLY Description Part 1 Dual Fork Assembly Dual l ork Assembly for SC series units EV WO016 SC p Not Shown 1 Dual Fork Assembly for SCT serics EV W016 SCT 1 units Not Shown Dual Front Wheel Axle 1 X 18 EV W017 3 Sleeve for SCT series Wide Tire units EV W007L Not Shown Spacer for SCT scrics Wide Tire units Not Shown 2 4 1 Flat Washer EV W027 6 1 Lock Washer EV W026 10 Tapered Roller Bearmg EV
22. IMS 1003 aduis pay coat 39059 90 Y3IdIM JILLOYHL uMoJg TYNOILIYNHU3ANI Dn 1H9nQv3H ads pay YUM 390 9 29 15 pay 6813 A3 JequinN HOLIMS 1V3S 15 pZ ON suondo ajnyy JONVS 8T 358 3138 anig Aa S9 M 204 IH JILLOYHL ajdung JILLOYHL 94115 pay adins pay pm monn 5 ds oy pay perg I 545 462 8 Ma m sduis 5 3481 o pay jeuondo t wey T 3 dn ypeg E eum B umoug 5 2 5 8 e b 5 P 3 5 5 1 I mE pay f psu gt 5 5 5 8 g DUM 7 pou pums 34 Owner s Manual and Service Guide PCT Series COMPONENTS ELECTRICAL PARTS LIST ELECTRICAL Part Number Key Switch 3 position Standard EV E100 Key Replacement set of 2 EV E160 Directional Switch 3 position Rocker EV E156 Horn EV E130 Horn Button 041 BDI 24 36 volt vehicles EV E241 10 Amp Fuse EV E015 Fuse Holder EV E016 Charger Receptacle
23. INDUSTRY STANDARDS 7 3 4 Operator Care of Personnel and Burden Carriers 7 3 4 1 Read and follow operators manual 7 3 4 2 At the beginning of each shift during which the carrier will be used the operator shall check the carrier condition and inspect the tires warning devices lights battery s and directional controllers brakes safety interlocks and steering mechanism If the carrier is found to be in need of repair or is in any way unsafe the matter shall be reported immediately to the user and the carrier shall not be operated until restored to safe operating condition 7 3 4 3 If during operation the carrier becomes unsafe in any way the matter shall be reported immediately to the user and the carrier shall not be operated until it has been restored to safe operating condition 7 3 4 4 Do not make repairs or adjustments unless specifically trained and authorized to do so 7 3 4 5 Before refueling the engine shall be stopped and allowed to cool The operator and passengers shall leave the carrier before refueling 7 3 4 6 Spillage of hazardous materials shall be contained immediately and addressed via appropriate hazardous materials regulations 7 3 4 7 Do not operate a carrier with a leak in the fuel system or battery s Battery s shall be charged and serviced per manufacturer s instructions 7 3 4 8 Do not use open flames for checking electrolyte level in storage battery s or liquid level in fuel
24. WO009 6 11 Bushing 1 X 125 X 0 625 EV WO011 I 15 Pin Cotter 3 16 1 1 4 EV W025 1 Owner s Manual and Service Guide Series 36 TRANSAXLE EXPLODED VIEW Owner s Manual and Service Guide PC amp PCT Series 37 TRANSAXLE PARTS LIST 4 Retaining Ring 3 6 Bearing Bal 1_ Bearing Bal 1_ 2 9 Bearing Ball T 2 intermediate Assembly 1 2_ 12 1_ Bearing 20 16 S v a 1_ i 1_ Serew Cover Plate vr 1 23 Brake Assembly LeftHand Shoe ype 1 Brake Assembly Left Hand Shoe Type Stock Chase 1 24 Brake Assembly Right Hand Shoe Type 1_ __ Brake Assembly Right Hand Shoe Stock Chase EVTOs s 1 CV 2 Ring Reining remm 2 4 39 Bearing Ball 2 39 Drum Brake Shug Shaf Lefi Hana aes 31 31 Shaf Lef Hand aes SSCS 1 32 stat ig angle 1 Owner s Manual and Service Guide PCT Series TRANSAXLE TROUBLESHOOTING
25. and complete a full discharge and charge cycle Check and add approved water only never acid if needed only after this first cycle is completed 2 Never discharge battery beyond 80 and do not operate battery if the specific gravity is below 1 150 3 If above 115 F 46 C allow battery to cool before charging or operating MAINTENANCE INSTRUCTIONS 4 During shipment or prolonged storage the electrolyte levels may fall below the separator protector Only after a complete discharge and charge cycle check and keep electrolyte level above separator Add approved water only when required and never add acid 5 Keep battery top clean dry and vent caps tightly in place 6 Keep open flame and metal objects away from battery top 7 Use only approved chargers of correct voltage and Current output 8 Keep battery compartment open and well ventilated during charge 9 Itis recommended that water be added to batteries near the end of the charge or after taking them to charge 10 Be sure to replace the vent caps after watering so electrolyte does not splash out ELECTROLYTE LEVELS Charge the batteries after each days use Clean the batteries and wire terminals Check that the electrolyte level is correct and add water as required It is important that the water used be pure and free of contaminants that could reduce the life of the battery by reducing the chemical reaction The water must be distilled or purified by an efficient
26. and whistles which only increase ownership costs The following core components make up the electrical portion of the vehicle Battery Charger Batteries shown on page 21 Motor Controller Battery Discharge Indicator BDI Speed Control Pedal Solenoid Circuit Breaker This section will cover each of these core components except batteries which is covered in the Maintenance section including troubleshooting AUTION AND GAPETY INSTRUCTIONS ERPRIWEHOED OY nmbeno OPERATE UNEVEN ere 25 Owner s Manual and Service Guide PCT Series COMPONENTS ELECTRICAL ONBOARD BATTERY CHARGER The onboard charger is air cooled eliminating any moving parts for increased reliability and life soan Because of this the mounting location has been designed to optimize air flow and it is important that this air flow is not inhibited in any way Regularly check the cooling fins to ensure they are free of dirt dust or other contaminants This section assumes your unit has the standard onboard Delta Q Battery Charger Figure 26 The charger is an IP66 NEMA4 enclosure and is designed for an operating temperature of 30 C to 50 C 22 F to 122 F It accepts AC input voltage range of 85 265 VAC with a nominal input voltage of 120 VAC or 230 VAC rms The input frequency range is 45 65 Hz with a maximum input cur
27. arrier Operator Responsibility 7 9 4 General Operator Responsibility 7 3 1 1 Read and follow operators manual 7 3 1 2 Do not operate carrier under the influence of drugs and alcohol 7 3 1 3Safeguard the pedestrians at all times Do not drive carrier in a manner that would endanger other persons 7 3 1 4 Riding on the carrier by persons other than the operator is authorized only on personnel seat s provided by the manufacturer All parts of each person s body shall remain within the plan view outline of the carrier 7 3 1 5 When a carrier is to be left unattended stop the carrier apply the parking brake stop the engine or turn off power turn off the control or ignition circuit and remove the key if provided Additionally for electric carriers the forward and reverse directional controls should be neutralized if a means is provided Block the wheels if the carrier is on an incline 7 3 1 6A carrier is considered unattended when the operator is 7 6m 25 ft or more from the carrier which remains in his view or whenever the operator leaves the carrier and it is not within his view When the operator 15 dismounted and within 7 6m 25 ft of the carrier still in his view he still must have controls neutralized and the parking brake s set to prevent movement 7 3 1 7 Maintain a safe distance from potential hazards such as edges of ramps and platforms 7 3 1 8Use only approved carriers in hazardous locations as defined
28. ch and there is no emergency reverse EMERGENCY REVERSE FORWARD REVERSE INTERLOCK i THROTTLE TYPICAL ELECTRO MAGNETIC A BRAKE AU MAIN KEY CONTACTOR WY TCH COIL POLARITY PROTECTION Ej POWER FUSE FIGURE 2 Diagnostics and Troubleshooting The controller provides diagnostics information to assist technicians in troubleshooting drive system problems The diagnostics information can be obtained by observing the appropriate display on the handheld programmer the fault message displayed on the Spyglass gauge the fault codes issued by the Status LED or the fault display driven by the controller s fault outputs Programming Diagnostics The handheld programmer presents complete diagnostic information in plain language Faults are displayed in the System Faults Menu and the status of the controller inputs outputs is displayed in the Monitor Menu Accessing the programmer s Fault History Menu provides a list of the faults that have occurred since the fault history file was last cleared Checking and clearing the fault history file is recommended each time the vehicle is brought in for maintenance For information on 1311 programmer operation contact Wesley for a user manual or download a copy of the manual from www packmule com Spyglass Diagnostics The eight character LCD on the Spyglass displays a continuous sequence of hour meter battery s
29. ck in the location indicated and carefully raise the front of the vehicle taking care that the rear wheels do not move Position jack stands in the locations indicated and slowly lower the vehicle to rest on the jack stands and test the stability of the vehicle Lifting the rear To remove a rear wheel or axle First raise the front of the vehicle as previously described and support on jack stands Then position the jack in the position indicated at the rear of the vehicle Carefully raise the rear of the vehicle with the jack and place two jack stands in the positions indicated Slowly lower the vehicle to rest on the jack stands and test the stability of the vehicle Lower the vehicle by reversing the lifting sequence Owner s Manual and Service Guide PC amp PCT Series LUBRICATION Proper lubrication will ensure maximum years of trouble free service from your Pack Mule Illustration of vehicle s lubrication points internal FIGURE 21 Front Fork and Steering Lubricate wheel bearings and fork pivot and steering bearing Figure 21 per the recommended maintenance schedule 22 MAINTENANCE INSTRUCTIONS Rear Axle Check fluid level in the rear axle per the recommended maintenance schedule The rear axle is provided with a fluid level check fill plug Figure 22 located at the bottom of the differential With the vehicle on level ground clean the area around the check fill plug and remove plug The correct flu
30. codes and ordinances Ventilation for internal combustion engine powered carriers shall be provided to remove flammable vapors gases fumes and other flammable materials Consult applicable fire codes for specific levels of ventilation Ventilation for electric powered carriers shall be provided to remove the accumulation of flammable hydrogen gas emitted during the battery charging process The amount of hydrogen gas emitted depends upon a number of factors such as the condition of the batteries the output rate of the battery charger and the amount of time the batteries are on charge Because of the highly volatile nature of hydrogen gas and its propensity to accumulate in pockets a minimum number of air changes per hour is required during charging Consult applicable fire and safety codes for the specific ventilation levels required as well as the use of explosion proof electrical apparatus SAE J1718 can be followed to check for hydrogen gas levels 6 5 Hazardous Locations 6 5 1 The user shall determine the hazard classification of the particular atmosphere or location in which the carrier is to be use in the accordance with ANSI NFPA 505 6 5 2 The user shall permit in hazardous areas only those carriers approved and of the type required by ANSI NFPA 505 6 6 Lighting for Operating Area The user in accordance with his responsibility to survey the environment and operating conditions shall determine if the carrier requires
31. ds Never get under a vehicle that is supported by a jack Lift the vehicle in accordance with the instructions in this manual Always test drive the vehicle after any repairs or maintenance in a safe area free of any other vehicles or pedestrians VENTILATION Hydrogen gas is generated in the charging cycle of batteries and is explosive in WARNING concentrations as low as 4 Because hydrogen gas is lighter than air it will collect in the ceilings of buildings and therefore proper ventilation is required Five air exchanges per hour is considered the minimum ventilation required Always use a dedicated circuit for each battery charger Do not permit other appliances to be plugged into the receptacle when the charger is in operation 7 Owner s Manual and Service Guide PC amp PCT Series INDUSTRY STANDARDS The following text is provided as recommended by Part Il For the User of ANSI ITSDF B56 8 2011 Safety Standard for Personnel and Burden Carriers The manufacturer strongly endorses the contents of this specification 6 GENERAL SAFETY PRACTICES 6 1 Introduction 6 1 1 Like other machines carriers can cause injury if improperly used or maintained Part contains broad safety practices applicable to carrier operation Before operation the user shall establish such additional specific safety practices as may reasonably be required for safe operation 6 1 2 Premise review The user shall periodically review their
32. ed in Lower the seat to close the battery compartment 2 Check for correct tire inflation pneumatic tires only 3 Inspect for fluid leaks 4 Ensure surrounding area is clear of all obstructions and everything properly stored and secured 5 Make sure you are properly seated in the operator s seat 6 Turn the key or on off switch to the ON position Be sure that the directional switch is in the neutral position and the accelerator pedal is not depressed Insert the key into the ignition switch if a key switch located on the instrument panel Turn the key completely to the right to the ON position or push the rocker or toggle switch to the ON position The indicator light on the BDI should come on If not do not attempt to operate the vehicle 7 Move the directional switch to the desired setting Push the rocker or toggle directional switch to either the forward or reverse position depress the left foot presence switch when equipped with this option 8 Press the speed control pedal Depress the speed control pedal with your foot in a controlled manner The speed of the vehicle will be proportional to the amount of pressure applied to the pedal The controller converts the signal form the accelerator regulating the speed acting as an automatic transmission 9 Stop Remove your foot from the speed control pedal and depress the separate brake pedal if needed to increase the stopping rate regenerative breaking 15 ac
33. ged It measures the specific gravity of the electrolyte liquid in the battery The electrolyte is about 1 260 in specific gravity when the battery is fully charged and about 1 100 in specific gravity when the battery is fully discharged 19 Owner s Manual and Service Guide PC amp PCT Series MAINTENANCE INSTRUCTIONS ROUTINE MAINTENANCE Before performing any maintenance repair work isolate the batteries from the motor and electronics by opening the circuit breaker in Figure 17 Simply push the red push button until the red side lever fully opens Figure 18 To close the circuit breaker simply push the red side lever to its original closed position Figure 17 Zt VOSI FIGURE 17 c O n O N lt Jg FIGURE 18 BATTERIES The standard batteries used on Pack Mule vehicles are a 36 or 48Volt battery This manual is written around lead acid batteries Batteries have a maximum life Therefore good maintenance is important to maximize the available life of the vehicle s batteries Owner s Manual and Service Guide PC amp PCT Series NWARNING Always wear approved safety goggles or face shield when handling or working around batteries BATTERY SAFETY Always observe the following warnings when working near batteries To prevent burns or battery explosion that could result in severe
34. gnated trainer who certifies the operator s ability to properly drive and park the vehicle under the conditions in which the vehicle will be used e Know how to properly load and unload cargo and passengers e Recognize maintenance problems SAFETY GUIDELINES All Pack Mule vehicles are designed for use on smooth surfaces in and around industrial plants and warehouses Not intended for agricultural use While made of components that are unaffected by the rain they are not intended for continuous outdoor use traversing up and down steep grades or travelling on public roads highways as the tires are not configured for these purposes Follow these guidelines to safely drive the vehicle Read understand and observe all labels affixed to the vehicle Do not start the vehicle without checking the brakes first Do not mount or dismount the vehicle when the key is in the ON position Do not drive the vehicle if the accelerator requires excessive pressure Do not park or operate the vehicle near flammable objects or in a flammable or hazardous environment Use only necessary power Keep both hands on the steering wheel while operating the vehicle Accelerate and decelerate slowly and in a controlled manner Always reduce speed to compensate for poor terrain or conditions Always maintain adequate distance between vehicles people and obstacles Do not use the vehicle to push objects Do not allow the tires to lose contact with the ground Proceed around
35. gure 1 either on the front of the vehicle near the switches the underside of the plate where the seat is mounted or inside the motor compartment attached to a side panel Whenever you correspond with Wesley International regarding FIGURE 1 your vehicle include this information LI Wesley International CHARGING BATTERIES Our Pack Mule electric vehicles come standard with an onboard charger They also come available with a slide out battery system in which case no onboard charger is included If your unit comes with the onboard charger place the vehicle in a well ventilated area and follow these steps to charge the battery 1 Position the vehicle within reach of an electrical outlet 2 Slide seat to the rear most position and tilt forward to open battery compartment 3 Check all battery cells for proper acid level Fluid should be above plates 4 Plug in the charger AC line cord Figure 2 which is already attached to the charger into a wall plug CAUTION Extension cords must be a 3 wire cord no longer than 30m 100 at 10AWG or 7 5m 25 at 16 AWQG per UL guidelines Only connect ONE charger to a single 15A circuit or the circuit may Figure 2 become overloaded Owner s Manual and Service Guide PC amp PCT Series VEHICLE CONTROLS METERS SWITCHES The controls meters and switches consist of Key Switch For vehicles equipped with key switch Fig
36. he work area in accordance with applicable regulations or local ordinance Handle fuel cylinders with care Physical damage such as dents scrapes or gouges may dangerously weaken the tank and make it unsafe for use Brakes steering mechanisms speed and directional control mechanisms warning devices lights governors guards and safety devices shall be inspected regularly and maintained in accordance with manufacturer s recommendations or devices designed and approved for hazardous area operation shall be inspected to ensure that maintenance preserves the original approved safe operating features m Fuel systems shall be checked for leaks and condition of parts If a leak is found action shall be taken to prevent the use of the carrier until the cause of the leak has been repaired n The carrier manufacturer s capacity operation and maintenance instruction plated tags or decals shall be maintained in legible condition o Batteries motors speed and directional controllers limit switches protective devices electrical conductors insulators and connections shall be inspected and maintained per carrier manufacturer s recommendation p Carriers shall be kept clean to minimize hazards and facilitate detection of components needing service q Modifications and additions which affect capacity and safe carrier operation shall not be performed without manufacturer s prior written authorization w
37. here authorized modifications have been made the user shall ensure that capacity operation warning and maintenance instruction plates tags or safety labels are changed accordingly Care shall be taken to ensure that all replacement parts are interchangeable with the original parts and of a quality at least equal to that provided in the original equipment 5 Disconnect batteries negative connection s first When reconnecting connect positive connection first t Hydraulic systems if so equipped shall be checked for leaks for condition of parts Keep body and hands away from pin holes or nozzles that eject fluids under high pressure Use paper or cardboard not hands to check for leaks Owner s Manual and Service Guide PC amp PCT Series OPERATING INSTRUCTIONS INITIAL CHECKLIST Use the following checklist to inspect and prep your vehicle prior to initial use 1 Check for evidence of leaking fluids i e battery acid or gear oil Check condition of tires and tire air pressure Maximum 90 psi Cold 60 psi recommended Pneumatic tires only Check to ensure wheel lug nuts are tight Check for tight corrosion free battery connections Check for smooth operation of controls switches and brakes Charge batteries Confirm that the brake fluid is at the proper level IDENTIFICATION The product model number serial number amp year of manufacture is located on a silver label Fi
38. id level is just below the bottom of the threaded hole If fluid levels are low add as required until it starts to seep from the hole Install the check fill plug FIGURE 22 To replace the fluid lift the vehicle per the lifting procedures Remove the rear axle cover and drain out the fluid into a container Clean cover mating surfaces as required with proper scraping tool Ensure cover lip is not bent Apply thin bead of RIV sealant and torque cover bolts 16 24 Ib ft Add 10 14 oz 80W 90 Hypoid gear oil through the check fill plug hole or until fluid just starts to seep from the hole BRAKES Service brakes per the recommended maintenance schedule The vehicle is equipped with rear drum brakes The parking brake is mechanically activated and the foot brake is hydraulically actuated Figure 23 shows the brake connections under the vehicle FIGURE 23 23 For the hydraulic brake upgrade the master cylinder can be accessed by removing the floor plate on the floor board as shown in Figure 24 1 4 f T 4 FIGURE 24 Twist the top on the master cylinder to remove the cap Figure 25 and check or re fill the hydraulic brake fluid 4 Fare 4 FIGURE 25 REGENERATIVE BRAKING Normal braking uses the regenerative braking which is activated by the release of the Speed Control Pedal The amount of regenerative braking or deceleration can be adjusted within the Cur
39. in the appropriate safety standards 7 3 1 9 Report all accidents to the user 7 3 1 10 Do not add to or modify the carrier 7 3 1 11 Carriers shall not be parked or left unattended such that they block or obstruct fire aisles access to stairways or fire equipment 7 3 1 12 Only operate carrier while within operator s station 7 3 2 Traveling 7 3 2 1 Observe all traffic regulations including authorized speed limits Under normal traffic conditions keep to the right Maintain a safe distance based on speed of travel from a carrier or vehicle ahead and keep the carrier under control at all times 7 3 2 2 Yield the right of way to pedestrians ambulances fire trucks or other carriers vehicles in emergency situations Owner s Manual and Service Guide PC amp PCT Series 7 3 2 3Do not pass another carrier or vehicle traveling in the same direction at intersections blind spots or at other dangerous locations 7 3 2 4 a clear view of the path of travel observe other traffic and personnel and maintain a safe clearance 7 3 2 5Slow down or stop as conditions dictate and activate the sound producing warning device at cross aisles and when visibility is obstructed at other locations 7 3 2 6 Ascend or descend grades slowly 7 3 2 7 Avoid turning if possible and use extreme caution on grades ramps or inclines normally travel straight up and down 7 3 2 8Under all travel conditions the carrier shall
40. itch in the NEUTRAL position when leaving the vehicle Battery Discharge Indicator BDI The battery discharge indicator Figure 7 communicates directly with the onboard controller and provides information on various system parameters such as battery state of charge operating hours on some models or maintenance status including error codes FIGURE 7 When powering on the vehicle the BDI first indicates the hours Note The controller is programmed to indicated traction hours which is the time that the motor is engaged and the vehicle is moving The controller can programmed to display key on hours which records time that the key switch is in the on position regardless of whether it is moving or not It then cycles through to the state of battery charge measured in percent charge remaining If there are any faults recorded by the controller the BDI will display an error code and the LED by the tool wrench symbol will illuminate 14 OPERATING INSTRUCTIONS Headlight Tail Light and Switch Optional Some vehicles may include the headlight and or tail light Figure 8 option In which case there will also be a rocker switch to turn the lights on or off Figure 9 FIGURE 8 Headlight Taillight Switch SPEED CONTROL PEDAL The speed control pedal Figure 10 is located to the right of the brake pedal It controls the speed of the vehicle and is operated with the right foot like the accelerator of an
41. l com www wesleyinternational com 5 Owner s Manual and Service Guide PC amp PCT Series SAFETY INFORMATION The responsibility of safety lies with four main groups manufacturers owners lessees operators and maintenance personnel This manual has been designed to assist the owner operator in operating and maintaining the vehicle in a safe manner in accordance with the procedures and standards to which the vehicle was designed and intended for use TRAINING Vehicle owners lessees are responsible for instructing their personnel in its safe operation Owner lessees must explain the vehicle s characteristics features operation of its controls and safe driving practices We strongly recommend that owners lessees first become familiar with the conditions of the place where the vehicle will be operated in order to assess 15 effect on safe operation Training should occur under the conditions of the operating environment while adhering to the safety guidelines and include Safety guidelines Operation of the vehicle under the conditions in which it will be operated Operation of all controls Safe driving practices A driving and operating test OPERATOR QUALIFICATIONS Operators should be selected based on their ability to safely operate the vehicle including vision hearing physical and mental capabilities Operators must e Demonstrate a working knowledge of all controls e Understand all safety guidelines e Be evaluated by a desi
42. lights and if so shall equip the carrier with appropriate lights 6 7 Control of Noxious Gases and Fumes When equipment powered by internal combustion engines is used in enclosed areas the atmosphere shall be maintained within limits specified in the American Conference of Governmental Industrial Hygienists publication Threshold Limit Values for Chemical Substances and Physical Agents in the Workroom Environment This may be accomplished by ventilation provided by the user or the installation use and proper maintenance of emission control equipment recommended or provided by the manufacturer of the equipment 6 8 Warning Device s 6 8 1 The user shall make periodic inspections of the carrier to be certain that the sound producing and or visual device s if equipped are maintained in good operating condition 6 8 2 The user shall determine if operating conditions require the carrier to be equipped with additional sound producing or visual devices or both and be responsible for providing and maintaining such devices in accordance with the manufacturer s recommendations 6 9 Safety Interlocks The user shall make periodic inspections of the carrier to be certain that the safety interlock system if so equipped is operating properly 7 OPERATING SAFETY RULES AND PRACTICES 7 1 Personnel and Burden Carrier Operator Qualifications Only persons who are trained in the proper operation of the carrier shall be authorized
43. n motor controller please contact Wesley International for a copy of the Sevcon controller manual or download a copy from www packmule com Upgrade kits are available from Wesley for those who wish to upgrade an older vehicle equipped with a Sevcon controller to a Curtis controller platform Contact Wesley s parts department for more information Programmable Parameters All Pack Mule vehicles leave the factory with standard default parameters programmed in the controller unless specific parameter settings requested at the time of order These parameters can be reprogrammed the field using a Curtis handheld programmer available from Wesley Generally there are five parameters which owners may want to modify to suit their specific safety or user preferences as follows a Acceleration Rate b Braking Rate Deceleration Rate d Maximum Forward Speed e Maximum Reverse Speed Acceleration Rate The acceleration rate defines the time it takes the controller to accelerate from 096 drive output to 10096 drive output A larger value represents a longer acceleration time and a gentler start Fast starts can be achieved by reducing the acceleration time i e by adjusting the acceleration rate to a smaller value The acceleration rate is adjustable from 0 1 to 3 0 seconds The default setting for this is 1 6 Braking Rate The braking rate defines the time it takes the controller to increase from 0 braking output to 100 b
44. n to Log Off the Supervisor Mode 9 Check out the new Supervisor PIN Press005432 1 ENTER You should be in Supervisor Mode You can now go to any menu by pressing the menu number and ENTER Remember This is an example You should change your Supervisor PIN to one known only to you 10 Determine Last user While in Supervisor Mode press 3 ENTER This places you in the Last User Menu as indicated by three red LED flashes Press ENTER again The LED flashes will indicate the last user The Green LED is for the 10 s digit The Red LED is for the 1 s digit Example 1 A single Red LED flash indicates User 01 last operated the vehicle Example 2 Two Green flashes and three Red flashes would indicate User 23 last operated the vehicle Press CE to leave the menu 11 Enable or Disable Maintenance Alarm Press 4 ENTER There will be four red LED flashes Press ENTER again If the Green LED flashes the alarm is enabled Press ENTER again and the Red LED will flash showing the alarm to be disabled Press ENTER again and the Green LED will flash showing the alarm to be again enabled 12 Listen to the maintenance alarm While in Menu 4 press 1 ENTER The maintenance alarm will sound Press CE to leave the menu Press CE again to Log Off the Supervisor Mode Note If the switch is left unattended in Supervisor mode it will automatically exit the mode after approximately one minute 13 If you are unable to get into the Supervisor m
45. nal 840 Spyglass display Two fault outputs provide diagnostics to remotely mounted displays Regenerative braking allows shorter stopping distances increases battery charge and reduces motor heating Automatic braking when throttle is reduced provides a compression braking feel and enhances safety Brake Drive Interlock meets 150 stopping distance requirements e Ramp restraint feature provides automatic electronic braking that restricts vehicle movement while in neutral Meets EEC fault detect requirements e Linear cutback of motor drive current during over temperature or under voltage Linear cutback of regenerative braking current during overvoltage High pedal disable HPD and static return to off SRO interlocks prevent vehicle runaway at startup Internal and external watchdog circuits ensure proper software operation Fully protected inputs and short circuit protected output drivers FIGURE 28 This manual covers the most commonly required information as it pertains to the Pack Mule vehicles For more detailed instructions contact Wesley International for a copy of the complete manual for the Curtis motor controller or download a copy from www packmule com 28 COMPONENTS ELECTRICAL Your Pack Mule vehicle should be equipped with one of the following Curtis motor controller models 36 Volt DC 48 Volt DC Curtis Model 1243 or 1268 Curtis Model 1268 If your vehicle is equipped with an older Sevco
46. ode after trying either the default PIN or a newly assigned PIN go back to Step 1 and reset the switch If all else fails or if you have questions about programming or installing the SAFE T LOCK call Tech Support at 1 800 241 2869 Directional Switch The directional rocker or toggle switch is used to place the vehicle in one of three operating modes forward reverse or neutral Figure 6 shows a rocker directional switch The directional switch MUST be in NEUTRAL center position BEFORE selecting vehicle ON or a Static Return to SRO error code will be generated by the motor controller The vehicle is temporarily immobilized as a standard safety feature f your vehicle is equipped with the Optional Foot Presence Switch and the unit is already turned on and in neutral position the foot presence switch MUST be engaged before the directional switch is placed in forward or reverse mode or the same error code will be displayed and the vehicle temporarily immobilized f this error code is displayed return the directional switch to the neutral position ensure the foot presence switch is engaged and Owner s Manual and Service Guide PC amp PCT Series then switch the directional Switch to the desired forward or reverse position and the vehicle will operate FIGURE 6 Directional Switch To prevent unexpected vehicle NWARNING movement when the vehicle is next driven always place the directional sw
47. of lubricant Lubricant level too high worn axle shaft seals cracked differential housing worn drive pinion gear shaft seal scored and worn yoke axle cover not properly sealed plugged vent or vent tube Axle overheating Lubricant level to low incorrect grade of lubricant contaminated lubricant bearing preload too high excessive gear wear insufficient ring gear backlash Overloading erratic clutch operation wheel spinning improper adjustment Insufficient lubricant incorrect backlash improper tooth contact worn damaged gears Axle noise Insufficient lubricant improper ring gear and drive pinion gear adjustment unmatched ring gear and drive pinion gear worn teeth on ring gear or drive pinion gear loose drive pinion gear shaft bearings loose differential bearings misalign ring and pinion gear loose differential bearing crap screws worn bearings Limited slip differential The most common problem is a chatter noise when turning corners The probable cause is incorrect or contaminated lubricant or lack of friction modifier additive in the lubricant Worn or damaged plates and discs plates and discs improperly assembled 39 Owner s Manual and Service Guide PC amp PCT Series HITCHES Owner s Manual and Service Guide PC amp PCT Series B x 5 40 MULE PROUDLY BUILT IN THE
48. ombined weight NWARNING of the driver and cargo Make sure the cargo is balanced and securely loaded Do not load cargo that can easily fall off the vehicle especially through turns Be very careful when handling cargo that is longer or wider than the vehicle Do not stack cargo so that the drivers view is obstructed This vehicle is not designed to carry passengers PARKING Place the directional switch in the park neutral position Turn the key switch to the off position Latch the parking brake the brake pedal If parking on an incline aim the front wheel toward the curb as shown in the diagram below C KS Owner s Manual and Service Guide PC amp PCT Series START UP CHECKLIST FOR INDUSTRIAL TRUCKS All industrial trucks that are used within Company are required to be inspected each day prior to use TRUCK NO OPERATOR DATE COMMENTS VENE Obvious damage Cracked frame welds Model tag readable Tires proper inflation and cut free Charging cord unplugged Wire insulation undamaged Battery connections Battery water level Horn switch must be turned on Battery discharge indicator If leaving vehicle turn off switch Owner s Manual and Service Guide PC amp PCT Series MAINTENANCE INSTRUCTIONS MAINTENANCE SCHEDULE Safe trouble free operation of your electric vehicle depends on regular and proper preventive maintenance The foll
49. operly installed hitch that matches the trailer tongue Optional hitches available from Wesley International Do not exceed the maximum towing capacity Do not exceed 5 mph when towing Take extreme care when towing down an incline Do not tow trailers down an incline with a grade of more than 15 MAINTENANCE Always maintain your vehicle in accordance with the service schedule within this manual and keep complete records of the maintenance history of the vehicle Ensure the maintenance personnel performing any service or repair work on the vehicle are trained and qualified to do so Be sure to disable the vehicle before performing any maintenance including removing the key from the key switch and removal of a battery cable NW ARNING Always insulate any tools used within the battery area in order to prevent sparks or battery explosion caused by shorting the battery terminals or associated wiring Be sure to check the polarity of each battery terminal and be sure to rewire the batteries correctly Never install a wire instead of a proper fuse even for a temporary fix It may cause extensive damage and possible fire Do not use a screwdriver or other metal object to remove fuses Doing so may cause an electrical short and damage the system Do not modify or tamper with any part of the operating or speed control systems All inspections and adjustments must be made by a qualified technician Always support the vehicle using wheel chocks and safety stan
50. ore changing the Supervisor PIN you are first going to add User locations For this example you will check on and add User location 01 as well as more User locations as required To do this you must go into the Add Delete User Menu 13 2 Go into Add Delete User Menu Press 2 ENTER There will be a beep along with two Red LED flashes indicating you are in Menu 2 Press 0 1 ENTER If there is a Red flash and a low beep it indicates that user location 01 has already been assigned To remove location 01 press ENTER again This will delete the location from use Add location 01 Press 0 1 ENTER You should now get a Green flash along with an up tone beep indicating the location is ready to be added or assigned to a user Press ENTER You will get a Green LED flash along with a beep The user location has been added At this point you can in the same way check on and add more user locations Before leaving Menu 2 check to make sure that location 01 and any others have been added Press 0 1 ENTER There should be a LED flash along with a low tone beep indicating the location has been assigned to the user Check any other locations you ve added the same way A Red flash along with a low tone beep means the location has been assigned A Green flash along with an up tone beep means the location is not assigned 3 Go out of Menu 2 Press CE The switch will indicate you are back in Supervisor Mode Press CE again to go out
51. owing chart is a guide for servicing your Pack Mule electric vehicle BI ANNUAL 125 Hours en 250 Hours SERVICE Check wheels for bent rims missing or loose lug nuts Check brake linkage Check brake linings and other components for wear and deterioration Check brake fluid level Oil all moving parts that do not have fittings with an oiler or brush SAE 30 oil Grease fork pivot fittings and gears with automotive grease using a grease gun Check and tighten all loose nuts and bolts Inspect steering gear housing and linkage Tighten as necessary Check oil level in transaxle Tighten any loose battery terminals and coat terminals with petroleum jelly Clean batteries amp terminals with 4 60 mL baking soda to 1 1 2 gal 6L water ensure charger is de energized Check electrolyte levels of all battery cells using hydrometer Clean inspect amp repack front axle and steering fork bearings with lithium based grease 1 In freezing temperatures recharge the batteries after adding distilled water to make sure the water mixes with the electrolyte properly Otherwise the water may freeze and damage the batteries Ihe recommended pneumatic tire pressure is 60 psi Over or under inflation can reduce tire life and adversely affect vehicle handling It may also lead to sudden tire failure which can result in the driver losing control of the vehicle A hydrometer is used to determine if a battery is properly char
52. rade existing vehicles FIGURE 5 The STL1000 switch allows plant and facility managers to input up to 99 different users drivers to track vehicle usage If accident occurs or the vehicle is damaged the manager can easily identify the last operator The switch also features an internal clock that records on hours and notifies the operator when the 250 hour mark is reached Each user can select a four to eight digit personal access code and a separate supervisor user menu programs the unit The switch will provide the last user ID code when prompted by the supervisor In operation only users with active ID codes can operate the vehicle virtually eliminating all unauthorized use the company said The switch operates in a voltage range from 9 to 120 volts DC and is enclosed in an IP65 rated housing Two internal LEDs indicate operational status red indicates an error or lock mode and green indicates key press or touch is active The unit also provides user feedback with key beep and error tones Step by Step Programming Instructions 1 Log onto the Supervisor Mode Press 0 0 1 2 3 4 ENTER Red and Green LED flashes along with an up tone beep indicate you are in the Supervisor Mode and ready to enter a Supervisor Mode menu Note As you enter each Supervisor Mode menu the number of Red LED flashes will correspond to the menu number For example one Red LED flash for menu 1 two Red LED flashes for menu 2 etc Bef
53. raking output as defined by the corresponding mode specific brake current limit when a new direction is selected A larger value represents a longer time and consequently gentler braking Faster braking is achieved by adjusting the braking rate to a smaller value The braking rate is adjustable from 0 1 second to 3 0 seconds The default setting for this is 0 1 Deceleration Hate The deceleration rate defines the time it takes the controller to reduce its output to the new throttle request when the throttle is reduced or released A lower value represents a faster deceleration and thus a shorter stopping distance The decel rate defines the vehicle s 29 Braking characteristic for any reduction in throttle including to neutral that does not include a request for the opposite direction The decel rate is adjustable from 0 1 to 10 0 seconds The default setting for this is 2 5 Maximum Forward Speed The maximum forward speed parameter defines the maximum controller voltage output at full throttle in the forward direction The maximum forward speed parameter is adjustable from the programmed creep speed up to 10096 The default setting for this is 70 which equates to about 7 mph 12 9 kph Maximum Reverse Speed The maximum reverse speed parameter defines the maximum controller voltage output at full throttle in the reverse direction The maximum reverse speed parameter is adjustable from 096 to 10096 The default setting for this is
54. rent of 12A and a nominal input current of 9 5A rms at 120 VAC or 5A rms at 230 VAC FIGURE 26 The charger includes an easy to read 10 LED display as follows LED Color Indication following Power On Self Test Ammeter AE Solid Displays approximate scale of current output during bulk phase Amber 5 1 Flashing High internal charger temperature Output reduced n E 80 Solid Bulk charge phase complete 80 charged In Absorption phase Amber EN With no battery connected indicates algorithm selected by Flashing number of flashes 10096 Charge Solid Charging complete Charger in Maintenance Mode Green Flashing Absorption phase complete In Finish phase AC On Solid AC power good Amber Flashing AC voltage Check voltage and extension cord length Fault lt Flashing Charger error Reset charger power and refer to trouble shooting Red instructions Owner s Manual and Service Guide PC amp PCT Series 26 COMPONENTS ELECTRICAL The optional charger Single LED display if included would be located on the front panel near the key switch LED Color Indication following Power On Self Test Green Solid Charging complete Charger in Maintenance Mode Flashing Short lt 80 Charge EN Long gt 80 Charge Ga temperature Red lt Flashing Charger error Reset charger power and refer to trouble shooting gt instruction
55. rottle Wiper Law input rerurns valkl range Check cantactar and ful d winding cycle Check wiring and contactor cycle KSI Owner s Manual and Service Guide PC amp PCT Series COMPONENTS ELECTRICAL Fault Codes and Troubleshooting Chart Table 7 TROUBLESHOOTING CHART cont d LOM BATTERY VOLTAGE Battery lt undervoltage curhack When rises abawe 1 Corraded bartery terminal undervaluge paint Lowe battery controller terminal 4 2 OVERVOLTAGE Battery val rage avervaltage shuklawn When voltage falls below limit avervaluge paint 1 Vehicle operating with charger attached 43 THERMAL CUTBACK Temperarure SAAC ar x 22570 Clears when heatsink 1 Excessive on vehick temperature ta 3 Impraper menting af cantraller within acceprable range 4 ANTI TIEDOWN 3 1 Mode switches sharted Ba 1 Mode 5elecr 1 ned down ta select Made 2 ar Made 4 permanently HOT 3 1 resistance gt mator har setpoint HO TOR 3 1 Fiekl resistance gt matar warm setpoint Owner s Manual and Service Guide PC amp PCT Series 5 BATTERY DISCHARGE INDICATOR The Curtis BDI Figure 29 shows the 24 36V version displays various system parameters such as battery state of charge operating hours or maintenance statie from the Curtis motor controller
56. s 1 Do not expose charger to oil mud or direct heavy water spray when cleaning vehicle 2 Ifthe detachable input power supply cord set is damaged replace with a cord that is a For North America UL or CSA listed approved detachable cord 3 conductor 16AWG minimum and rated SJT terminating in a grounding type IEC 60320 C14 plug rated 250V 13A minimum b For all other countries a safety approved detachable cord 3 conductor 1 5mm minimum rated appropriately for industrial use The cord set must terminate on one end with a grounding type input connector appropriate for use in the country of destination and on the other end an output grounding type IEC 60320 C14 plug 3 The enclosure of the charger has been tested successfully to EN60529 meeting IP66 The AC supply inlet is rated to IP20 which is suitable for indoor use only Keep all AC connections clean and dry If a fault occurs count the number of red flashes between pauses and refer to the following table Red Flashes Cause Solution 9 Battery High Voltage Check battery size and condition and reset charger interrupt power for 15 seconds SESE Battery High Voltage Gheok battery size and condiion and reset charger interrupt power for 15 seconds g 2 2 Charge Timeout caused by battery Check connections See pack not reaching required voltage Charger output was reduced due to Operate charger at a lower ambient tempera
57. ser to follow safety practices also ground and floor conditions grade speed loading the operation of the carrier with improper loads battery weight dynamic and static forces and the judgment exercised by the carrier operator a The user shall train carrier operators to adhere strictly to the operating instructions stated in this Standard b The user shall survey specific operating conditions and environment and establish and train carrier operators to comply with additional specific safety practices Owner s Manual and Service Guide PC amp PCT Series 6 3 Nameplates Markings Capacity and Modifications 6 3 1 The user shall maintain in a legible condition all nameplates warnings and instructions which are supplied by the manufacturer 6 3 2 Except as provided in 6 3 4 no modifications or alterations to a carrier which may affect the capacity stability or safe operation of the carrier shall be made without the prior written approval of the original carrier manufacturer or a successor thereof When the carrier manufacturer or its successor approves a modification or alteration appropriate changes shall be made to capacity plates decals tags and operation and maintenance manuals 6 3 3 As required under paragraphs 6 3 1 or 6 3 2 the manufacturer shall be contacted to secure new nameplates warnings or instructions which shall then be affixed in their proper place on the carrier 6 3 4 In the event tha
58. t the carrier manufacturer is no longer in business and there is no successor in interest to the business the user may arrange for a modification or alteration to a carrier provided however the controlling party shall 1 Arrange for the modification or alteration to be designed tested and implemented by an engineer s expert in carrier s and their safety 2 Maintain a permanent record of the design test s and implementation of the modification or alteration 3 Make appropriate changes to the capacity plate s decals tags and operation and maintenance manuals 4 Affix a permanent and readily visible label on the carrier stating the manner in which the carrier has been modified or altered together with the date of the modification or alteration and the name of the organization that accomplished the tasks 6 4 Changing and Charging Storage Batteries for Electric Personnel and Burden Carriers 6 4 4 The user shall require battery changing and charging facilities and procedures to be in accordance with ANSI NFPA 505 or as required by local ordinance 6 4 2 The user shall periodically inspect facilities and review procedures to be certain that ANSI NFPA 505 or as required by local ordinance are strictly complied with and shall familiarize carrier operators with it INDUSTRY STANDARDS 6 4 3 Maintenance and storage areas for carriers shall be properly ventilated to avoid fire hazards in accordance with applicable fire
59. tanks 8 MAINTENANCE PRACTICES 81 Introduction Carriers may become hazardous if maintenance 15 neglected Maintenance facilities trained personnel and procedures shall be provided Such facilities may be on or off the premises 8 2 Maintenance Procedures Maintenance and inspection of all carriers shall be performed in conformance with the following practices and should follow the manufacturer s recommendations a A scheduled preventive maintenance lubrication and inspection system shall be followed b Only trained and authorized personnel shall be permitted to maintain repair adjust and inspect carriers c Before undertaking maintenance or repair follow the manufacturers recommendations for immobilizing the carrier d Chock wheels and support carrier before working underneath it e Before disconnecting any part of the engine fuel system be sure the shutoff valve if so equipped is closed and follow carrier manufacturer s recommended practice f Operation to check performance of the carrier shall be conducted in an authorized area where suitable conditions exist free of vehicular and pedestrian traffic g Before returning carrier to service follow the manufacturer s instructions and recommended procedures h Avoid fire hazards and have fire protection equipment present in the work area Do not use an open flame to check level or leakage of fuel battery electrolyte or coolant i Properly ventilate t
60. tate of charge and fault messages Fault messages are displayed using the same codes that are flashed by the LED For example the LED flashes 3 2 for a welded main contactor And the corresponding Spyglass message is When a fault message is being displayed the red Fault LED labeled with a wrench symbol flashes to catch the operator s attention Owner s Manual and Service Guide PC amp PCT Series 30 COMPONENTS ELECTRICAL Fault Codes and Troubleshooting Chart Table TROUBLESHOOTING CHART LEQ PROCES CODE LOO POS FAULT CLEARANCE no __ Pao CURRENT SHUNT FAULT HM FAILSAFE H SHORTED R EM THROTTLE WIPER HI REY WIRING SRYC TOTAL SRYC TRAC TOTAL DISABLED TRAC DISABLED THROTTLE WIPER LO FIELD SHORT mw CONT WELDED d ED CONTACT OR 5 31 1 Abnormal vehicle causing high current spikes 2 Current sensar aut af range 3 Controller 1 enviranment 2 Self test ar watchdog fault 3 Controller Internal ar external shart of Be rect wirmg 3 Controller 3 poe interlock and direcrian inputs 2 Interlock ar direcrion switch circuit apen 3 cr ra short 4 Wrong SRO or throat sdected 5 Misadjusted thronle pot 3 Defective throttle pot 3 Wrong throttle
61. tis Motor Controller See instructions on Page 29 Owner s Manual and Service Guide PC amp PCT Series MAINTENANCE INSTRUCTIONS TIRES AND WHEELS The PCT series has a 5 000 Ib tow capacity The transaxle has a five bolt pattern for the wheels The following tire options are offered with the PCT series vehicle Pneumatic tires standard 2 Foam filled tires 3 Solid tires black 4 Solid non marking tires off white 5 Soft solid tires Pneumatic tires are tubeless tires filled with air and mounted on one piece rims They offer the smoothest ride but do require regular maintenance to ensure proper air levels are maintained and require immediate repair should they go flat Foam filled tires replace the air inside pneumatic tires with a foam compound and are mounted on one piece rims This retains the smoother ride of pneumatic tires but eliminates the regular maintenance associated with pneumatic tires However if a vehicle equipped with foam filled tires sits for extended periods of time flat soots may form Solid tires are solid rubber compound mounted on a two piece rim They eliminate the possibility of flat spots and the maintenance associated with pneumatic tires but because they are solid they do not provide as smooth a ride as pneumatic tires Solid non marking tires operate in the same manner but are made of a rubber compound that prevents black marks on floors Soft Solid tires are a rubber wheel
62. tivated by releasing the speed control pedal TOWING Attach a suitable hitch to match the trailer being towed Wesley International offers a variety of hitches to choose from so you can find one suitable for your application Make sure the hitch is properly installed and secured Attach the trailer to the hitch and the trailer safety chains to the provided safety chain holes Wesley offers a variety of towing capacities Do not exceed the specified towing capacity of the vehicle The maximum tow capacity includes the combined weight of the trailers the cargo on the trailers and the weight of the driver and cargo on the vehicle Do not exceed 5 mph 8 kph when towing NWARNING COASTING To prevent injury or death resulting from coasting at above recommended speeds limit speed with service brake On steep ramps or hills it is possible for the vehicle to coast at faster than normal speeds than may be encountered on a flat surface To prevent loss of vehicle control speeds should be limited to no more than the maximum speed on level ground Limit speed by removing your foot from the speed control pedal amp applying pressure on the separate brake pedal LOADING UNLOADING Make sure the vehicle has come to a full stop before embarking disembarking or before loading unloading any cargo Turn off the vehicle when loading unloading cargo Do not exceed the load capacity of the vehicle The maximum load capacity includes the c
63. ture high temperatures e 9 Check Battery Battery could not be Check for shorted or damaged cells vu wat trickle charged up to minimum voltage 9 9 9 9 9 Over Temperature Charger shut Ensure sufficient cooling air flow and reset charger Ss down due to high internal interrupt AC power for 15 seconds temperature 9 9 9 V ow Charger Internal Fault VAN ZEN ZEN Reset charger interrupt AC power for 15 seconds If fault persists likely needs to be replaced 27 Owner s Manual and Service Guide PC amp PCT Series COMPONENTS ELECTRICAL STANDARD All Pack mule electric vehicles are equipped with Advanced Motor and Drives DL Series Separately Excited DC motors The motor Field and Armature are completely separate and are energized independently by the motor controller See Figure 27 FIGURE 27 CONTROLLER The PCT Series electric vehicle is equipped with a Curtis separately excited Sep Ex motor speed controller See Figure 28 These programmable controllers are simple to install efficient and cost effective The Curtis controller provides smooth precise control of motor speed and torque A full bridge field control stage is combined with a half bridge armature power stage to provide solid state motor reversing and full regenerative braking without additional relays or contactors The controllers rugged IP53 ho
64. ure 3 the vehicle only operates when the key is in the switch It has two positions run and off Key Switch Perma Key Switch or On Off Switch FWD REV Directional Selector Switch Battery Discharge Indicator BDI Headlight Tail Light Switch Optional Parking Brake Speed Control Pedal Brake Pedal Horn Button Seat Presence Sensor Switch Foot Presence Switch Optional Key Switch FIGURE 3 Perma Key Switch Optional An optional Perma Key switch is available to replace the standard key switch works the same way but eliminates the need for a separate key that may get lost It has three positions run off and charge only On Off Rocker Switch Optional An optional 2 position on off Rocker switch is available to replace the standard key switch Figure 4 gt On Off Switch FIGURE 4 12 OPERATING INSTRUCTIONS NWARNING To prevent unexpected vehicle movement unauthorized use always turn the key switch to the OFF position and remove key when the vehicle is not in use Programmable Security Switch Optional SAFE T LOCK is a programmable code switch Figure 5 which prevents unauthorized use of the vehicle It is offered as an option part number EV E901 The SAFE T LOCK switch is installed in lieu of the standard switch to control access and operation of the vehicle within the customer s premises can be pre installed at time of order or purchased separately to upg
65. using and packaging are built to with stand shock and vibration The controller is fully programmable through the Curtis 13XX handheld programmer In addition to configuration flexibility the programmer provides diagnostic and test capability The Curtis motor controller offers superior operator control of the vehicle s motor drive speed Features include e nterlock braking with load sensor to meet required braking distance without unnecessary harsh braking at light loads e Maintenance monitor responds to preset vehicle operating hours and drive hours as programmed by the OEM e Two hour meters total KSl on hours and traction hours and the associated maintenance timers are built into the controller BDI calculations performed within controller Estimates motor temperature based on field resistance and cuts back maximum speed if the motor is overheated e Diagnostic checks for field open and field shorted faults Owner s Manual and Service Guide PC amp PCT Series e Supports PWM electromagnetic brake with maximum continuous current of 2 amps e Supports Type 4 throttle Active pre charge of controller capacitor bank extends life of main contactor Compatibility with Curtis handheld programmers for quick and easy testing diagnostics and parameter adjustment e Continuous armature current control reducing arcing and brush wear Complete diagnostics through the handheld programmer the built in Status LED and the optio

Pack-Mule-Manual-PC

Contents

Download Pdf Manuals

Related Search

Related Contents