INDUSTRIAL ELECTRIC VEHICLE OWNER’S MANUAL AND SERVICE GUIDE PCT-SERIES Nov 2013 Owner’s Manual and Service Guide – PC & 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.
TABLE OF CONTENTS INTRODUCTION ................................................................................................................................................................................ 5 SAFETY INFORMATION .................................................................................................................................................................... 6 Training ...........................................................................................................
Controller ...................................................................................................................................................................................... 28 Battery Discharge Indicator (BDI) ................................................................................................................................................. 33 Speed Control Pedal.................................................................................................................
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.
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. T RAINING Vehicle owners/lessees are responsible for instructing their personnel in its safe operation.
SAFETY INFORMATION Good common sense and prudent driving practices do more to prevent accidents and injuries than all of the warnings and instructions combined.
INDUSTRY STANDARDS The following text is provided as recommended by Part II, “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 II contains broad safety practices applicable to carrier operation.
INDUSTRY STANDARDS 6.4.3 Maintenance and storage areas for carriers shall be properly ventilated to avoid fire hazards in accordance with applicable fire 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.
INDUSTRY STANDARDS 7.3 Personnel and Burden Carrier Operator Responsibility 7.3.1 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. 7.3.1.3 Safeguard 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.
INDUSTRY STANDARDS 7.3.4 Operator Carriers Care of Personnel and Burden 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), speed and directional controllers, brakes, safety interlocks, and steering mechanism.
OPERATING INSTRUCTIONS I NITIAL C HECKLIST Use the following checklist to inspect and prep your vehicle prior to initial use. □ □ □ □ □ □ □ 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.
OPERATING INSTRUCTIONS WARNING To prevent unexpected vehicle movement or 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-TLOCK™ is a programmable code switch,( Figure 5), which prevents unauthorized use of the vehicle. It is offered as an option, part number EV-E901.
OPERATING INSTRUCTIONS then switch the directional Switch to the desired forward or reverse position and the vehicle will operate. 8 – Go out of Menu 1. Press CE. Press CE again to Log Off the Supervisor Mode. 9 – Check out the new Supervisor PIN. Press 0 0 5 4 3 2 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.
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). F IGURE 8 F IGURE 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.
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. F IGURE 15 F IGURE 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. .
OPERATING INSTRUCTIONS C OASTING D RIVING To prevent injury or death resulting from coasting at above recommended speeds, limit speed with service brake. Follow these steps to operate your Pack Mule vehicle: 1) 2) 3) 4) 5) 6) 7) 8) 9) Disconnect the battery charger. Unplug the battery charger from the 110V wall plug (vehicle will not operate when plugged in). Lower the seat to close the battery compartment. Check for correct tire inflation (pneumatic tires only). Inspect for fluid leaks.
START UP CHECKLIST FOR INDUSTRIAL TRUCKS All industrial trucks that are used within <> are required to be inspected each day prior to use. TRUCK NO.
MAINTENANCE INSTRUCTIONS M AINTENANCE S CHEDULE Safe trouble-free operation of your electric vehicle depends on regular and proper preventive maintenance. The following chart is a guide for servicing your Pack Mule electric vehicle.
WARNING MAINTENANCE INSTRUCTIONS R OUTINE M AINTENANCE Before performing any CAUTION maintenance or 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) Always wear approved safety goggles or face shield when handling or working around batteries.
MAINTENANCE INSTRUCTIONS 4) 5) 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. 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.
MAINTENANCE INSTRUCTIONS WARNING L IFTING THE V EHICLE L UBRICATION Proper lubrication will ensure maximum years of trouble free service from your Pack Mule. Illustration of vehicle’s lubrication points (internal) 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 go beneath a vehicle while it is supported by a crane or jack. Use jack stands and test the stability of the vehicle.
MAINTENANCE INSTRUCTIONS 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. 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.
MAINTENANCE INSTRUCTIONS T IRES AND W HEELS The PCT series has a 5,000 lb tow capacity. The transaxle has a five bolt pattern for the wheels. The following tire options are offered with the PCT series vehicle: 1) 2) 3) 4) 5) Pneumatic tires (standard) Foam-filled tires Solid tires (black) Solid non-marking tires (off-white) Soft solid tires Replacing Rear Tires/Wheels: To remove and repair the rear tires and/or wheels, complete the following steps: 1) 2) 3) 4) Loosen the lug nuts on the wheel.
COMPONENTS - ELECTRICAL B ASIC E LECTRICAL C OMPONENTS 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 and whistles” which only increase ownership costs.
COMPONENTS - ELECTRICAL O NBOARD B ATTERY C HARGER This section assumes your unit has the standard onboard Delta-Q Battery Charger (Figure 26). The onboard charger is air cooled, eliminating any moving parts for increased reliability and life span. 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.
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 1) 2) 3) Solid: Charging complete. Charger in Maintenance Mode. Flashing: Short: <80% Charge Long: >80% Charge Amber Flashing: Reduced power mode: Low AC voltage or High internal charger temperature. Red Flashing: Charger error. Reset charger power and refer to trouble shooting instructions.
COMPONENTS - ELECTRICAL STANDARD M OTOR 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) F IGURE 27 C ONTROLLER The PCT Series electric vehicle is equipped with a Curtis separately excited (Sep Ex) motor speed controller.
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 Sevcon motor controller, please contact Wesley International for a copy of the Sevcon controller manual, or download a copy from www.packmule.com.
COMPONENTS - ELECTRICAL Controller Wiring: Typical Controller wiring configuration of PC series vehicles. The interlock switch is a seat switch or foot switch and there is no emergency reverse. F IGURE 2 Diagnostics and Troubleshooting: The controller provides diagnostics information to assist technicians in troubleshooting drive system problems.
COMPONENTS - ELECTRICAL Fault Codes and Troubleshooting Chart: 31 Owner’s Manual and Service Guide – PC & PCT Series
COMPONENTS - ELECTRICAL Fault Codes and Troubleshooting Chart: Owner’s Manual and Service Guide – PC & PCT Series 32
COMPONENTS – ELECTRICAL Speed Control Pedal BA TTERY D ISCHARGE I NDICATOR (BDI) The speed control pedal (Figure 31) is a rugged assembly with IP66 throttle sensor protection for reliable use in harsh industrial environments. The Curtis BDI (Figure 29) shows the 24/36V version) displays various system parameters, such as battery state-of-charge, operating hours or maintenance status from the Curtis motor controller. There are no user serviceable parts in the speed control pedal.
COMPONENTS - ELECTRICAL W IRING D IAGRAM Owner’s Manual and Service Guide – PC & PCT Series 34
COMPONENTS - ELECTRICAL P ARTS L IST – A VAILABLE O PTIONS P ARTS L IST – E LECTRICAL Part Part Number Part Part Number Key Switch, 3-position (standard) EV-E100 Perma-Key Switch EV-E194PK Key Replacement, set of 2 EV-E160 On/Off Switch EV-E017 Directional Switch, 3 position Rocker EV-E156 Programmable Code Security Switch EV-E901 Horn EV-E130 Headlight/Taillight Switch, Rocker EV-E155 Horn Button EV-E041 Single LED Charge Status Plate EV-E808L BDI – 24 / 36 volt vehicles EV-E241
COMPONENTS - MECHANICAL P ARTS L IST – F RONT W HEEL S TEER A SSEMBLY Owner’s Manual and Service Guide – PC & PCT Series 36
TRANSAXLE – EXPLODED VIEW 37 Owner’s Manual and Service Guide – PC & PCT Series
TRANSAXLE PARTS LIST Owner’s Manual and Service Guide – PC & PCT Series 38
TRANSAXLE TROUBLESHOOTING 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.
HITCHES Owner’s Manual and Service Guide – PC & PCT Series 40
PROUDLY BUILT IN THE USA 41 Owner’s Manual and Service Guide – PC & PCT Series
