INDUSTRIAL ELECTRIC VEHICLE OWNER’S MANUAL AND SERVICE GUIDE SC & SCT SERIES APRIL 2014 Owner’s Manual and Service Guide – SC & SCT 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 ...........................................................................................................
Battery Discharge Indicator (BDI) ................................................................................................................................................. 33 Throttle Position Device ................................................................................................................................................................ 33 Solenoid ...................................................................................................................................
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 Loading and Unloading Follow these guidelines when loading and unloading cargo: 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 Be extremely careful carrying loads that extend beyond the vehicle’s deck T OWING Follow these guidelines when towing: Turn the vehicle off when connecting equipment that will be towed Always
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 7.3.2.2 Yield the right of way to pedestrians, ambulances, fire trucks, or other carriers/vehicles in emergency situations. 7.3 Personnel and Burden Carrier Operator Responsibility 7.3.2.3 Do not pass another carrier or vehicle traveling in the same direction at intersections, blind spots, or at other dangerous locations. 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.
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 V EHICLE C ONTROLS , M ETERS , S WITCHES Use the following checklist to inspect and prep your vehicle prior to initial use. The controls, meters and switches consist of: □ □ □ □ □ □ Check for evidence of leaking fluids, i.e. brake fluid, 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 the key when the vehicle is not in use Programmable Security Switch (Optional): SAFE-TLOCK™ is a programmable code switch, shown in Figure 5, which prevents unauthorized use of the vehicle. It is offered as an option, part number EV-E901.
OPERATING INSTRUCTIONS engaged, and 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 Combination Accelerator/Brake Pedal: To Accelerate: Depress the accelerator (Figure 10) with the right foot. The speed of the vehicle will be proportional to the amount that the accelerator pedal is depressed.
OPERATING INSTRUCTIONS Horn and Horn button: The horn button is located at the top of the left side of the instrument panel. It is operated by the left hand. The horn (Figure 11) will not sound when the key or on/off switch is in the off position. F IGURE 11 Back-Up Alarm (Optional): Optionally, a back-up may be installed on the vehicle.. The back-up alarm (Figure 12) only sounds when the directional switch is placed in the reverse position. .
OPERATING INSTRUCTIONS D RIVING Follow these steps to operate your Pack Mule vehicle: 1) 2) 3) 4) 5) 6) 7) Disconnect the battery charger. Remove the battery charger cord from the power outlet. Perform Startup Checklist for Industrial Trucks (see next page for checklist). Ensure surrounding area is clear of all obstructions and everything properly stored and secured. Make sure you are standing on the operator platform, holding the steering wheel.
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.
MAINTENANCE INSTRUCTIONS CAUTION R OUTINE M AINTENANCE Before performing any maintenance or repair work, isolate the batteries from the motor and electronics by opening the circuit breaker in (Figure 13). Simply push the red push button until the red side lever fully opens as shown in Figure 14. To close the circuit breaker, simply push the red side lever to its original closed position. (Figure 13) Hydrogen gas forms when charging batteries. Do NOT charge batteries without adequate ventilation.
MAINTENANCE INSTRUCTIONS 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) It is 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. E LECTROLYTE L EVELS Charge the batteries after each days use.
MAINTENANCE INSTRUCTIONS WARNING L IFTING THE V EHICLE 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. Always place chocks in front and behind the wheels not being raised.
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 18) 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 fluid 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.
MAINTENANCE INSTRUCTIONS Replacing Front Tires/Wheels: To remove and repair the front tires and/or wheels, complete the following steps: 1) 2) 3) 4) 5) Remove the axle nut retaining clip. Lift the front of the vehicle as explained in the “Lifting the Vehicle” Section. Loosen the axle nuts and remove the entire wheel, hub and axle assembly from front fork. Remove the lug nuts and remove the wheel from the axle assembly. Reinstall the repaired or replacement tire by reversing the above sequence.
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 20). If your vehicle has a previous model charger, please refer to the support section of our website at www.packmule.com for the applicable user’s guide. The onboard charger is air cooled, eliminating any moving parts for increased reliability and life span.
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 M OTOR All Pack mule electric vehicles are equipped with Advanced Motor and Drives “DL” Series Separately Excited DC motors (Figure 21). The motor Field and Armature are completely separate and are energized independently by the motor controller. F IGURE 21 C ONTROLLER The PC Series electric vehicle is equipped with a Curtis separately excited (Sep Ex) motor speed controller (Figure 22). These programmable controllers are simple to install, efficient, and cost effective.
COMPONENTS - ELECTRICAL Your Pack Mule vehicle should be equipped with one of the following Curtis motor controller models: 24 Volt DC: 36 Volt DC: 48 Volt DC: 36 Volt AC: 48 Volt AC: Curtis Model 1243 Curtis Model 1243 or 1268 Curtis Model 1268 Curtis Model 1234 Curtis Model 1234 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. Diagnostics and Troubleshooting: The controller provides diagnostics information to assist technicians in troubleshooting drive system problems.
COMPONENTS - ELECTRICAL Fault Codes and Troubleshooting Chart: Table 7 TROUBLESHOOTING CHART LED CODE PROGRAMMER FAULT CATEGORY POSSIBLE LCD DISPLAY CAUSE 0,1 NO KNOWN FAULTS 0 1,1 CURRENT SHUNT FAULT 1 1,2 HN FAILSAFE 1 1,3 M - SHORTED 1 1,4 SRO 3 2,1 THROTTLE WIPER HI 1 2,2 EMR REV WIRING 1 2,3 HPD 3 SRVC TOTAL 3 SRVC TRAC TOTAL DISABLED TRAC DISABLED 3 3 3 2,4 THROTTLE WIPER LO 1 3,1 FIELD SHORT 1 3,2 MAIN CONT WELDED 1 3,3 FIELD OPEN 1 3,4 MISSING CONTACTO
COMPONENTS - ELECTRICAL Fault Codes and Troubleshooting Chart: Table 7 TROUBLESHOOTING CHART, cont’d LED CODE PROGRAMMER FAULT CATEGORY POSSIBLE LCD DISPLAY 4,1 LOW BATTERY VOLTAGE FAULT CLEARANCE CAUSE 2 1. Battery voltage < undervoltage cutback. When voltage rises above undervoltage cutoff point. 2. Corroded battery terminal. 4,2 OVERVOLTAGE 2 4,3 THERMAL CUTBACK 2 3. Loose battery or controller terminal. 1. Battery voltage > overvoltage shutdown limit. 2.
COMPONENTS - ELECTRICAL B ATTERY D ISCHARGE I NDICATOR (BDI) THROTTLE POSITION DEVICE The Curtis BDI (Figure 23 shows the 24/36V version) displays various system parameters, such as battery stateof-charge, operating hours or maintenance status from the Curtis motor controller. The throttle position device (Figure 25) is a rugged assembly with IP66 throttle sensor protection for reliable use in harsh industrial environments.
COMPONENTS – ELECTRICAL W IRING D IAGRAM Owner’s Manual and Service Guide – SC & SCT Series 34
COMPONENTS - ELECTRICAL P ARTS L IST – E LECTRICAL Part 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 EV-E041 BDI – 24 / 36 volt vehicles EV-E241 BDI – 48 volt vehicles EV-E241-802 Solenoid, 4-terminal 24V EV-E014HD Solenoid, 4-terminal 36V EV-E064HD Solenoid, 4-terminal 48V EV-E204 HD 10 Amp Fuse EV-E015 Fuse Holder EV-E016 Charger Receptacle EV-E027 Charger Cord EV-
COMPONENTS - ELECTRICAL P ARTS L IST – A VAILABLE O PTIONS Part Part Number Perma-Key Switch EV-E194PK On/Off Switch EV-E017 Programmable Code Security Switch EV-E901 Headlight/Taillight Switch, Rocker EV-E155 Single LED Charge Status Plate EV-E808L Foot Presence Switch EV-E128 Battery Watering System – 24V GC135 EV-E900-6 Battery Watering System – 24V GC145 EV-E900-7 Battery Watering System – 36V GC135 EV-E900-2 Battery Watering System – 36V GC145 EV-E900-1 Battery Watering System – 4
COMPONENTS – MECHANICAL - PARTS LIST – FRONT WHEEL STEER ASSEMBLY # 1 1 1 2 3 3 4 4 5 6 7 8 8 9 10 11 12 13 14 15 16 37 Description Dual Fork Assembly Dual Fork Assembly, for SC series units (Not Shown) Dual Fork Assembly, for SCT series units (Not Shown) Dual Front Wheel Axle, 1” X 18” Sleeve Sleeve, for SCT series/Wide Tire units (Not Shown) Spacer Spacer, for SCT series/Wide Tire units (Not Shown) 1” Flat Washer 1” Lock Washer 1” Slotted Hex Nut Hub with 4 Studs Hub with 5 Studs Race, Bearing Tapered R
ACCELERATOR LINKAGE Owner’s Manual and Service Guide – SC & SCT Series Item Description 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166 Wave Spring Swivel Rod Cotter Pin, 1/8’ (2) Locknut (2) Threaded Rod Nut, 5/16’ Ball Joint Spring (3) 1/2 Yoke End, Left (2) Brake Rod, 1/2" (2) 1/2 Yoke End, Left (2) Clevis Pin, 1/2" (4) Lockwasher, 1/2" (2) Cotter Pin (4) 1/2" -20 Hex Nut (2) Flat Washer 1/2" (4) Part Number EV-G065 EV-G064 EV-D016 AA-73 EV-G062 EV-G015 EV-G063 EV-D006 EV-D001 EV-D0
Transaxle Diagram for SC Series 39 Owner’s Manual and Service Guide – SC & SCT Series
Transaxle Parts List for the SC Series # Part Part Number QTY See Kit 1 3 Gear, Input 4 Ring, Retaining EV-T016 3 5 O-Ring EV-T014 3 6 Bearing, Ball EV-T015 1 7 Bearing, Ball EV-T013 1 8 Plug, End Cap EV-T017 2 9 Bearing, Ball EV-T011 2 10 Gear, Intermediate Assembly See Kit 1 11 O-Ring EV-T010 2 12 Gear, Final Drive 13 Bearing, Ball EV-T008 2 15 Screw, Cap EV-T006 4 16 Nut, Lock EV-T007 4 17 Plate, Cover EV-T018 1 18 Plug, Fill EV-T020 1 19 Scr
Transaxle Diagram for the SCT Series 41 Owner’s Manual and Service Guide – SC & SCT Series
Transaxle Parts for SCT Series # Part Part Number QTY See Kit 1 3 Gear, Input 4 Ring, Retaining EV-T016 3 5 O-Ring EV-T014 3 6 Bearing, Ball EV-T015 1 7 Bearing, Ball EV-T013 1 8 Plug, End Cap EV-T017 2 9 Bearing, Ball EV-T011 2 10 Gear, Intermediate Assembly See Kit 1 11 O-Ring EV-T010 2 12 Gear, Final Drive See Kit 1 13 Bearing, Ball EV-T008 2 15 Screw, Cap EV-T006 4 16 Nut, Lock EV-T007 4 17 Plate, Cover EV-T018 1 18 Plug, Fill EV-T020 1 19
ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 43 PART NUMBER EV-D011 EV-D018 EV-E183PD EV-F8186 EV-F8188 EV-G001 EV-G012 EV-G023 EV-G027 EV-G043 EV-G066 DESCRIPTION Washer, Split Lock, 1/2” ID Washer, 1/2"ID SAE Zn Beacon, Pedestal Base Pole, Beacon Mount Plate, Beacon Base Mount 10-32 x 1/2” PHMS Nut, Hex, 1/2-13 Zn Plated Locknut, Nylon Insert, 10-32 1/2-13 x 3.0” RHSN Gr.2 Plug, Tube End, 1 x 2 Washer, Rivet, 3/16 ID QTY.
PROUDLY BUILT IN THE USA Owner’s Manual and Service Guide – SC & SCT Series 44
