pack-mule-pc
INDUSTRIALELECTRICVEHICLE
OWNER’SMANUAL
ANDSERVICEGUIDE
PCƒ†
SERIES
2012
NOTES,CAUTIONSANDWARNINGS
Throughout this guide NOTE, CAUTION, and WARNING will be used. Please observe these notes, cautions and warnings.
NOTE
A NOTE indicates a condition that should be observed.
CAUTION
A CAUTION indicates a condition that may result in damage to the vehicle.
WARNING
A WARNING indicates a hazardous condition that could result in severe injury or death.
TableofContents
INTRODUCTION ................................................................................................................................................................................ 5
SAFETY INFORMATION .................................................................................................................................................................... 6
Training ........................................................................................................................................................................................... 6
Operator Qualifications ................................................................................................................................................................... 6
Safety Guidelines............................................................................................................................................................................ 6
Loading and Unloading ................................................................................................................................................................... 7
Towing ............................................................................................................................................................................................ 7
Maintenance ................................................................................................................................................................................... 7
Ventilation ....................................................................................................................................................................................... 7
INDUSTRYSTANDARDS....................................................................................................................................................................... 8
OPERATINGINSTRUCTIONS .............................................................................................................................................................. 13
Initial Checklist .............................................................................................................................................................................. 13
Identification ................................................................................................................................................................................. 13
Charging ....................................................................................................................................................................................... 13
Vehicle Controls, Meters, Switches .............................................................................................................................................. 13
Driving .......................................................................................................................................................................................... 19
Coasting ....................................................................................................................................................................................... 19
Loading/Unloading ........................................................................................................................................................................ 19
Parking ......................................................................................................................................................................................... 19
Towing .......................................................................................................................................................................................... 19
MAINTENANCEINSTRUCTIONS ......................................................................................................................................................... 20
Maintenance Schedule ................................................................................................................................................................. 20
Routine Maintenance .................................................................................................................................................................... 21
Batteries ....................................................................................................................................................................................... 21
Battery Safety ............................................................................................................................................................................... 21
Battery Care ................................................................................................................................................................................. 21
Electrolyte Levels.......................................................................................................................................................................... 22
Battery Watering System .............................................................................................................................................................. 22
Cleaning Batteries ........................................................................................................................................................................ 22
Battery Replacement .................................................................................................................................................................... 22
Lifting the Vehicle ........................................................................................................................................................................ 23
Lubrication .................................................................................................................................................................................... 23
Brakes .......................................................................................................................................................................................... 24
Tires and Wheels .......................................................................................................................................................................... 24
COMPONENTSELECTRICAL............................................................................................................................................................. 26
Basic Electrical Components ........................................................................................................................................................ 26
Onboard Battery Charger ............................................................................................................................................................. 27
Motor ............................................................................................................................................................................................ 29
Controller ...................................................................................................................................................................................... 29
Battery Discharge Indicator (BDI) ................................................................................................................................................. 34
Speed Control Pedal..................................................................................................................................................................... 34
3
Owner’s Manual and Service Guide – PC Series
Solenoid ........................................................................................................................................................................................ 34
Wiring Diagram ............................................................................................................................................................................. 35
Parts List – Electrical .................................................................................................................................................................... 36
Parts List – Available Options ....................................................................................................................................................... 36
COMPONENTSMECHANICAL .......................................................................................................................................................... 37
Parts List – Front Wheel Steer Assembly ..................................................................................................................................... 37
Transaxle
............................................................................................................................................. Owner’s Manual and Service Guide – PC 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.
R ECORD Y OUR P RODUCT I NFORMATION Model #:
Serial #:
Purchase Date:
R EGISTER Y OUR P RODUCT 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! And it will entitle you to free parts for any defective items, as outlined in our warranty document.
R EAD T HIS M ANUAL Before operating or working on your new vehicle, read this manual to become familiar with the safety guidelines, operating
instructions, and maintenance procedures.
I F Y OU N EED H ELP 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 [email protected] or call (800) 241-2869 or (404) 292-7441.
Wesley International
3680 Chestnut Street
Scottdale, GA 30079
Phone (404) 989-7441 • Toll Free (800) 241-2869 •
[email protected]
www.wesleyinternational.com
5
Fax (404) 292-8469
Owner’s Manual and Service Guide – PC Series
SAFETYINFORMATION
The responsibility of safety lies with four main groups: manufacturers, owners, 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 are responsible for instructing their personnel in its safe operation. Owners must explain the vehicle’s
characteristics, features, operation of its controls, and safe driving practices. We strongly recommend that owners first become
familiar with the conditions of the place where the vehicle will be operated in order to assess its effect on safe operation. Training
should occur under the conditions of the operating environment while adhering to the safety guidelines and include:
x
x
x
x
x
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
O PERATOR Q UALIFICATIONS Operators should be selected based on their ability to safely operate the vehicle, including vision, hearing, physical and mental
capabilities. Operators must:
x
x
x
x
x
Demonstrate a working knowledge of all controls
Understand all safety guidelines
Be able to properly drive and park the vehicle under the conditions in which the vehicle will be used
Know how to properly load and unload cargo and passengers
Recognize maintenance problems
S AFETY G UIDELINES All Pack Mule vehicles are designed for use on smooth surfaces in and around industrial plants, warehouses, nurseries and
greenhouses. They are not intended for use outdoors, up and down steep grades, or on public roads and highways.
Follow these guidelines to safely drive the vehicle:
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
Read this manual before operating 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 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.
Never abruptly change direction
Always drive directly up an incline; never across
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, speeds should be limited to no more than maximum speed on level ground.
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.
Owner’s Manual and Service Guide – PC Series
6
SAFETYINFORMATION
Wesley International LLC reserves the right to make design changes without obligation to make these changes on units previously
sold and the information contained in this manual is subject to change without notice.
Wesley International LLC is not liable for errors in this manual or for incidental or consequential damages that result from the use
of the material in this manual.
L OADINGAND U NLOADING Follow these guidelines when loading and unloading cargo:
x
x
x
x
x
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:
x
x
x
x
x
Turn the vehicle off when connecting equipment that will be towed
Always use a properly installed hitch (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
M AINTENANCE 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.
WARNING
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 stands. 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.
Wesley recommends that only OEM replacement parts be used. Using any parts other than those approved by Wesley may result
in the warranty being made void.
V ENTILATION WARNING
Hydrogen gas is generated in the charging cycle of batteries and is explosive in 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 Series
INDUSTRYSTANDARDS
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.
6.3 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 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. 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 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.”
(b) 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 user 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 Series
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 that 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 Fuel Handling and Storage
6.4.1 The user shall supervise the storage and handling
of liquid fuels (when used) to be certain that it is in
accordance with ANSI/NFPA 505 and ANSI/NFPA 30 or as
required by local ordinance.
6.4.2 Storage and handling of liquefied petroleum gas
fuels shall be in accordance with ANSI/NFPA 505 and
ANSI/NFPA 58 or as required by local ordinance. If such
storage or handling is not in compliance with these
standards, the user shall prevent the carrier from being used
until such storage and handling is in compliance with these
standards.
6.4.3 Prevent fire and explosion caused by static electric
discharge. Use only non-metal, portable fuel containers
approved by the Underwriter's Laboratory (U.L.) or the
American Society for Testing & Materials (ASTM). If using a
funnel, make sure it is plastic and has no screen or filter.
8
INDUSTRYSTANDARDS
Static electric discharge can ignite gasoline vapors in an
ungrounded fuel container. Remove the fuel container from
the bed of a carrier or the trunk of a car and place on the
ground away from the carrier before filling. Keep nozzle in
contact with container opening while filling.
When practical, remove equipment from trailers or truck
beds and re-fuel them on the ground. If this is not possible,
use a portable, plastic fuel container to refuel equipment on
a truck bed or trailer.
6.5 Changing and Charging Storage Batteries for
Electric Personnel and Burden Carriers
6.5.1 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.
6.5.2 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.
6.5.3 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.
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.
6.6 Hazardous Locations
6.6.1 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.
6.6.2 The user shall permit in hazardous areas only those
carriers approved and of the type required by ANSI/NFPA
505.
9
6.7 Lighting for Operating Area
The user, in accordance with his responsibility to survey the
environment and operating conditions, shall determine if the
carrier requires lights and, if so, shall equip the carrier with
appropriate lights.
6.8 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.
6.9 Warning Device(s)
6.9.1 The user shall make periodic inspections of the
carrier to be certain that the sound-producing and/or visual
device(s) if so equipped are maintained in good operating
condition.
6.9.2 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.
6.10 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 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.
Owner’s Manual and Service Guide – PC Series
INDUSTRYSTANDARDS
7.2.3 The user shall include as a minimum in the
operators’ training program the following:
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.
(a) 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.
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. 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.
7.3.1.6 A 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 is
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.
7.3.1.8 Use only approved carriers in hazardous locations,
as defined in the appropriate safety standards.
7.3.1.9 Report all accidents to the user.
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 or vehicles in emergency
situations.
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.
7.3.2.4 Keep a clear view of the path of travel, observe
other traffic and personnel, and maintain a safe clearance.
7.3.2.5 Slow 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.
7.3.2.8 Under all travel conditions the carrier shall 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.
7.3.2.13 Avoid running over loose objects, potholes, and
bumps.
7.3.1.10 Do not add to, or modify, the carrier.
Owner’s Manual and Service Guide – PC Series
10
INDUSTRYSTANDARDS
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.
8 MAINTENANCE PRACTICES
8.1 Introduction
Carriers may become hazardous if maintenance is
neglected. Maintenance facilities, trained personnel, and
procedures shall be provided. Such facilities may be on or
off the premises.
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.
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. If the carrier is found to
be in need of repair or in any way unsafe, 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.
7.3.4.3 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 tanks.
11
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
manufacturer’s 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 the work area in accordance with
applicable regulations or local ordinance.
(j) Handle fuel cylinders with care. Physical damage,
such as dents, scrapes, or gouges, may dangerously
weaken the tank and make it unsafe for use.
(k) 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.
(l) Special carriers 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 to 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 in a clean condition to minimize
hazards and facilitate detection of components needing
service
Owner’s Manual and Service Guide – PC Series
INDUSTRYSTANDARDS
(q) Modifications and additions which affect capacity and
safe carrier operation shall not be performed without
manufacturer’s prior written authorization; where authorized
modifications have been made, the user shall ensure that
capacity, operation, warning, and maintenance instruction
plates, tags, or safety labels are changed accordingly.
(r) 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.
(s) 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 Series
12
OPERATINGINSTRUCTIONS
may become overloaded.
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. 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.
Charge batteries.
Check that all battery connections are tight.
Check for smooth operation of controls, switches, and
brakes.
I DENTIFICATION The product model number, serial
number, and year of manufacture is
located on a silver label as shown in
Figure 1, either on the front of the
vehicle near the switches, on the
underside of the plate where the seat
is mounted, or inside the motor
compartment attached to a side
panel.
F IGURE 1
V EHICLE C ONTROLS , M ETERS , S WITCHES The controls, meters and switches consist of:
x
x
x
x
x
x
x
x
x
x
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: For vehicles equipped with a key switch, Figure
3, the vehicle only operates when the key is in the switch. It
has three positions – run, off, and charge only.
Whenever you correspond with
Wesley International regarding your
vehicle, be sure to include this
information.
C HARGING 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 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 the charger AC line cord into the IEC
receptacle located on the rear of the vehicle (Figure
2), and the other end into the wall receptacle
CAUTION:
Extension
cords must be a 3-wire
cord no longer than 30m
(100’) at 10AWG or 7.5m
(25’) at 16 AWG per UL
guidelines. Only connect
ONE charger to a single
15A circuit or the circuit
F IGURE 3
Perma-Key Switch (Optional): An optional Perma-Key
switch is available to replace the standard key switch. It
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.
On/OffSwitch
F IGURE 4
F IGURE 2
13
Owner’s Manual and Service Guide – PC Series
OPERATINGINSTRUCTIONS
required. To do this you must go into the Add / Delete User
Menu.
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.
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.
Programmable Security Switch (Optional): SAFE-TLOCK™ is a programmable code switch, as shown in Figure
5, which prevents unauthorized use of the vehicle, and 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. It can
be pre-installed at time of
order,
or
purchased
separately
to
upgrade
existing vehicles.
F IGURE 5
The STL1000 switch allows
plant and facility managers to input up to 99 different
users/drivers to track vehicle usage. If an 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
vehicle reaches the 250-hour mark.
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.
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.
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.
WARNING
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.
Before 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
Owner’s Manual and Service Guide – PC Series
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 Red 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 of
Supervisor Mode. (CE can be pressed several times to make
sure you are completely clear and ready to enter the next
mode.)
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 5 4 3 2 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 0 1 5 4 3 2 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
1 2 3 4 default.)
7 – Log back onto the Supervisor Mode to change the
Supervisor PIN. Press 0 0 1 2 3 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.
14
OPERATINGINSTRUCTIONS
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. 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.
DirectionalSwitch
F IGURE 6
WARNING
To prevent unexpected vehicle
movement when the vehicle is
next driven, always place the
directional switch in the
NEUTRAL
position
when
leaving the vehicle.
Battery Discharge Indicator (BDI): The battery discharge
indicator, shown in 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.
13 – If you are unable to get into the Supervisor mode 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 1-800241-2869.
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 Off” (SRO) error code will be generated by the motor
controller. The vehicle is temporarily immobilized as a
standard safety feature. Also, if 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. If this error code is
displayed, the operator simply needs to turn the directional
switch back to neutral, ensure the foot presence switch is
NOTE
15
F IGURE 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 be
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.
Owner’s Manual and Service Guide – PC Series
OPERATINGINSTRUCTIONS
Headlight / Tail-Light and Switch (Optional): Some
vehicles may include the headlight (Figure 9) and/or tail-light
(Figure 8) option. In which case, there will also be a rocker
switch to turn the lights on or off. An example of this switch
on the PC-300 model is shown in Figure 10.
F IGURE 8
F IGURE 11
F IGURE 9
Headlight/TaillightSwitch
F IGURE 12
F IGURE 10
Parking Brake (Optional): The parking brake lever is lifted
up to place the parking brake on as shown in Figure 11 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 13. Turning the handle clockwise loosens
the tension. Be careful not to over tighten or the life of the
brake cable may be shortened.
F IGURE 13
Owner’s Manual and Service Guide – PC Series
16
OPERATINGINSTRUCTIONS
Speed Control Pedal: The speed control pedal, Figure 14,
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 automobile. Depressing the pedal
starts the motor. Releasing the pedal stops the motor.
Reverse speed is half of forward speed.
F IGURE 16
F IGURE 14
F IGURE 17
Horn and Horn button: The horn button is either located on
the right hand handle bar, or for tiller steering, on the left
side of the floor board. Both work the same way and controls
the horn which is located in the rear compartment, mounted
to the top of the left rear wheel well. If mounted on the
handle bars as shown in Figure 18, the horn button is
operated by hand. If mounted on the floor board as shown
in Figure 19, it is foot operated.
Brake Pedal: The brake pedal, Figure 15, 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.
F IGURE 18
F IGURE 15
Where a separate parking brake is not included, the brake
pedal has a brake lock feature which can lock the brake
pedal into the down position as shown in Figure 16, thus
acting as a parking brake. Simply push the brake pedal all
the way down while pushing at the bottom edge of the brake
pedal. This will engage the black pedal lock to latch onto the
body frame, retaining the brake pedal in the engaged
position.
To release, simply push the top edge of the brake pedal and
the brake pedal will disengage and be free to move to its
disengaged position, as shown in Figure 17.
17
F IGURE 19
The horn (Figure 20) will not sound when the key or on/off
switch is in the off position.
Owner’s Manual and Service Guide – PC Series
OPERATINGINSTRUCTIONS
F IGURE 20
F IGURE 22
Back-Up or Proximity Alarm (Optional): Optionally, a
back-up or proximity alarm may be installed on the vehicle if
it was ordered with this option as shown in Figure 21. The
back-up alarm only sounds when the directional switch is
placed in the reverse position. The proximity alarm sounds
when the directional switch is placed in either the forward or
reverse position.
Foot Presence Switch (Optional): The foot presence
switch, if present as shown in Figure 23, 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 operator’s
foot leave the foot presence switch during while the vehicle
is moving, the motor will disengage and the vehicle will slow
to a stop.
F IGURE 21
Seat Presence Sensor Switch: The presence sensor
switch is located under the seat as shown in Figure 22 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.
F IGURE 23
Owner’s Manual and Service Guide – PC Series
18
OPERATINGINSTRUCTIONS
D RIVING level ground. Limit speed by removing your foot from the
speed control pedal and applying pressure on the separate
brake pedal.
Follow these steps to operate your Pack Mule vehicle:
1)
2)
3)
4)
5)
6)
7)
8)
9)
Disconnect the battery charger.
Remove the battery charger cord from the power outlet.
Disconnect the charger cord from the charger
receptacle located on the rear of the vehicle and place
the charger cord in its holder under the rear cargo deck.
Check for correct tire inflation (pneumatic tires
only).
Inspect for fluid leaks.
Ensure surrounding area is clear of all obstructions
and everything properly stored and secured.
Make sure you are properly seated in the operator’s
seat.
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.
Move the directional switch to the desired setting.
Push the rocker or toggle directional switch to either the
forward or reverse position.
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.
If the directional switch remains in the
NOTE FORWARD or REVERSE position for
more than 10 seconds without
depressing the speed control pedal, the safety delay
feature engages, and the vehicle will not move. The
operator must place the directional switch to neutral,
and then select the desired direction to resume motion.
Stop
Remove your foot from the speed control pedal and
depress the separate brake pedal.
L OADING /U NLOADING WARNING
Make sure the vehicle has come
to a complete stop before
passengers embark/disembark or
before loading/unloading any
cargo. Turn off the vehicle when
loading/unloading cargo. Do not
exceed the specified number of
passengers or load capacity of
the vehicle. The maximum load
capacity includes the combined
weight of the passengers 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
driver’s view is obstructed.
P ARKING Place the directional switch in the PARK/NEUTRAL position.
Turn the key switch to the OFF position. If parking on an
incline, block the wheels to prevent the vehicle from rolling
forward or backward.
T OWING Attach one of the available hitches provided by Wesley
International. 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. 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 combined weight of the
passengers and cargo on the vehicle. Do not exceed 5 mph
/ 8 kph when towing.
C OASTING WARNING
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 that 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
19
Owner’s Manual and Service Guide – PC Series
MAINTENANCEINSTRUCTIONS
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.
SERVICE
Check all gauges, horn, and lights (if present)
Check BDI for battery charge
Plug-in battery charger when vehicle is not in
1
service; Leave to charge overnight, if possible
Check all battery cells for water levels after charging
Check tires for cuts, excessive wear, and pressure
2
(check pressure when tires are cold )
Check wheels for bent rims, missing or loose lug
nuts
Check brake linkage; Check brake linings and other
components for wear and deterioration
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 (SAE 80-90 oil)
Tighten any loose battery terminals and coat
terminals with petroleum jelly
Clean batteries & terminals with ¼ cup (60 mL)
baking soda to 1 ½ gal (6L) water; ensure charger is
de-energized
Check electrolyte levels of all battery cells using
3
hydrometer
Change oil in transaxle (SAE 80W-90 oil; 18 oz/0.5L)
Clean, inspect, & repack front axle and steering fork
bearings with lithium based grease
Lubricate steering drive chain; Check for wear
DAILY
WEEKLY
MONTHLY
20 Hours
BI-ANNUAL
125 Hours
ANNUAL
250 Hours
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
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.
2
The 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.
3
A hydrometer is used to determine if a battery is properly charged. 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.
Owner’s Manual and Service Guide – PC Series
20
MAINTENANCEINSTRUCTIONS R OUTINE M AINTENANCE WARNING
Before
performing
any
maintenance or repair work,
isolate the batteries from the
motor and electronics by opening the circuit breaker
shown in Figure 24. Simply push the red push button
until the red side lever fully opens as shown in Figure
25. To close the circuit breaker, simply push the red
side lever to its original closed position.
CAUTION
To prevent burns or battery
explosion that could result in
severe 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. 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 as shown in Figure 24 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.
Always wear approved safety goggles or
face shield when handling or working
around batteries.
F IGURE 24
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 ¼ cup (60 mL)
sodium bicarbonate (baking soda) dissolved in 1 ½
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 the batteries terminals, which can
short the battery, which could result in an explosion and
severe personal injury or death.
F IGURE 25
B ATTERIES The standard batteries used on Pack Mule vehicles are 6
volt lead acid. Other battery options are available such as
AGM dry-cell batteries. This manual is written around the
more common lead acid batteries.
Batteries have a
maximum life. Therefore, good maintenance is important to
maximize the available life of the vehicle’s batteries.
B ATTERY C ARE 1)
2)
3)
4)
B ATTERY S AFETY Always observe the following warnings when working on or
near batteries:
21
Place battery into service 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.
Never discharge battery beyond 80% and do not
operate battery if the specific gravity is below 1.150
If above 115o F (46o C) allow battery to cool before
charging or operating
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 and 1/8” (3.175mm)
Owner’s Manual and Service Guide – PC Series
5)
below vent well. 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.
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. 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 filtration system.
Electrolyte level should be ½” (13 mm) above the plates in
each cell. This level will leave about ¼” – 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.
MAINTENANCEINSTRUCTIONS
watering system attached to the batteries (Figure 26).
Elevate the gravity feed container at least 3 feet (1 m) to
properly fill the batteries.
C LEANING B ATTERIES 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
which should consist of ¼ cup (60 mL) of sodium
bicarbonate mixed with 1 ½ gallons (6 L) of water. Allow the
solution to sit for at least three minutes. Rinse the entire
area with low pressure clear water.
B ATTERY R EPLACEMENT Remove battery hold downs and cables. Lift out batteries
with a commercially available lifting device.
Use care to connect the battery terminals in the proper
manner as shown. Tighten the battery post hardware to 5070 in. lbs. (6-8 Nm) torque. Protect the battery terminals and
battery wire terminals with a commercially available
lubricant.
B ATTERY W ATERING S YSTEM Wesley International offers a battery watering system, shown
in Figure 26, as an option on all its vehicles. This system is
a fast, accurate, and safe means of maintaining precise
electrolyte levels in the batteries.
F IGURE 26
To use the watering system, simply
container shown in Figure 27 with a
Connect the blue connector at the end
tubing to the blue connector at the
fill the gravity feed
clean water source.
of the container flow
end of the battery
Owner’s Manual and Service Guide – PC Series
22
MAINTENANCEINSTRUCTIONS
L UBRICATION Proper lubrication will ensure maximum years of trouble free
service from your Pack Mule.
L IFTINGTHE V EHICLE WARNING
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 crawl under a
vehicle while it is supported by
a 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 3point wheel design which is
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.
Front Wheels and Fork: Lubricate wheel bearings and fork
pivot, per the recommended maintenance schedule.
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 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.
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 jack 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.
23
Fill Plug
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 RTV sealant and torque cover bolts 16-24 lb-ft.
Owner’s Manual and Service Guide – PC Series
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.
MAINTENANCEINSTRUCTIONS
Twist the top on the master cylinder to remove the cap
(Figure 29) and check or re-fill the hydraulic brake fluid.
B RAKES Service brakes per the recommended maintenance
schedule. The vehicle is equipped with mechanical drum
brakes.
These brakes are either mechanically or
hydraulically actuated. For vehicles with the hydraulic
upgrade, a ¾” hydraulic piston is added between the cable
coming from the brake pedal and the cables coming from the
drum brakes on the transaxle as in Figure 27.
F IGURE 29
MAINTENANCEINSTRUCTIONS
T IRESAND W HEELS F IGURE 27
For the hydraulic brake upgrade, the master cylinder can be
accessed by removing the floor plate on the floor board as
shown in Figure 28.
The PC series is offered in two tow capacity versions: 2,000
pound (907 kg) tow capacity standard transaxle and 5,000
pound (2,268 kg) tow capacity tugger transaxle. The
standard transaxle has a four bolt pattern for the wheels,
whereas the tugger transaxle has a five bolt pattern.
The following tire options are offered with the PC series
vehicle:
1)
2)
3)
4)
Pneumatic tires (standard)
Foam-filled tires
Solid tires (black)
Solid non-marking tires (off-white)
Pneumatic tires are tubeless tires filled with air and mounted
on one piece rims. Pneumatic tires offer the smoothest ride
but do require regular maintenance to ensure proper air
levels are maintained and require immediate repair should
they go flat.
F IGURE 28
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 eliminate the
regular maintenance associated with pneumatic tires.
However, if a vehicle equipped with foam-filled tires sits for
extended periods of time, flat spots may form.
Solid tires are solid rubber compound mounted on a two
piece rim. They eliminate the possibility of flat spots and the
Owner’s Manual and Service Guide – PC Series
24
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.
Replacing Front Tires/Wheels: To remove and repair the
front tires and/or wheels, complete the following steps:
1)
2)
3)
4)
5)
6)
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.
Completely deflate the tire, then remove from the
wheel.
Reinstall the repaired or replacement tire by
reversing the above sequence. Tighten to 70 to 80
ft. lbs. (95 to 108 Nm) torque.
Replacing Rear Tires/Wheels: To remove and repair the
rear tires and/or wheels, complete the following steps:
1)
2)
3)
4)
5)
Loosen the lug nuts on the wheel.
Lift the rear of the vehicle as explained in the
“Lifting the Vehicle” Section.
Remove the lug nuts and remove the wheel from
the transaxle.
Completely deflate the tire, then remove from the
wheel.
Reinstall the repaired or replacement tire by
reversing the above sequence. Tighten to 70 to 80
ft. lbs. (95 to 108 Nm) torque.
25
Owner’s Manual and Service Guide – PC Series
COMPONENTSELECTRICAL
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. The following core components make up
the electrical portion of the vehicle:
1)
2)
3)
4)
5)
6)
7)
8)
Onboard Battery Charger
Batteries (shown on page 22)
Motor
Controller
Battery Discharge Indicator (BDI)
Speed Control Pedal (shown on page 34)
Solenoid
Circuit Breaker
This section will cover each of these core components (except batteries which is covered in the Maintenance section), including
troubleshooting.
8
4
7
1
3
5
Owner’s Manual and Service Guide – PC Series
26
COMPONENTSELECTRICAL
O NBOARD B ATTERY C HARGER This section assumes your unit has the standard onboard
Delta-Q Battery Charger as shown Figure 30.
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. 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.
The charger is an IP66 (NEMA4) enclosure and is designed
for an operating temperature of -30oC to +50o C (-22o F to
o
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 current of 12A and a nominal input current of 9.5A rms
at 120 VAC or 5A rms at 230 VAC.
F IGURE 30
The charger includes an easy to read 10-LED display as follows:
LED Color
Ammeter
(Amber)
80% Charge
(Amber)
100% Charge
(Green)
AC On
(Amber)
Fault
(Red)
27
Indication (following “Power-On Self Test”)
Solid:
Displays approximate scale of current output during bulk phase.
Flashing:
High internal charger temperature. Output reduced.
Solid:
Bulk charge phase complete, 80% charged. In Absorption phase.
Flashing:
With no battery connected, indicates algorithm # selected by
number of flashes.
Solid:
Charging complete. Charger in Maintenance Mode.
Flashing:
Absorption phase complete. In Finish phase
Solid:
AC power good.
Flashing:
Low AC voltage. Check voltage and extension cord length.
Flashing:
Charger error. Reset charger power and refer to trouble shooting
instructions.
Owner’s Manual and Service Guide – PC Series
COMPONENTSELECTRICAL
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.
Do not expose charger to oil, mud or direct heavy water spray when cleaning vehicle.
If the 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; or
2
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.
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
Battery High Voltage
Check battery size and condition and reset charger
(interrupt AC power for 15 seconds).
Battery High Voltage
Check battery size and condition and reset charger
(interrupt AC power for 15 seconds).
Charge Timeout caused by
battery pack not reaching
required voltage. Charger
output was reduced due to
high temperatures.
Check connections.
Check Battery: Battery could
not be trickle charged up to
minimum voltage
Check for shorted or damaged cells.
Over-Temperature: Charger
shut down due to high internal
temperature.
Ensure sufficient cooling air flow and reset charger (interrupt
AC power for 15 seconds).
Charger Internal Fault
Reset charger (interrupt AC power for 15 seconds). If fault
persists, likely needs to be replaced.
Owner’s Manual and Service Guide – PC Series
Operate charger at a lower ambient temperature.
28
COMPONENTSELECTRICAL
M OTOR All Pack mule electric vehicles are equipped with Advanced
Motor and Drives “DL” Series Separately Excited DC motors
as pictured in Figure 31. The motor Field and Armature are
completely separate and are energized independently by the
motor controller.
F IGURE 31
C ONTROLLER The PC Series electric vehicle is equipped with a Curtis
separately excited (Sep Ex) motor speed controller. 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.
x Supports PWM electromagnetic brake with maximum
continuous current of 2 amps
x Supports Type 4 throttle
x Active pre-charge of controller capacitor bank extends life
of main contactor
x Compatibility
with
Curtis
1307/1311
handheld
programmers for quick and easy testing, diagnostics, and
parameter adjustment
x Continuous armature current control, reducing arcing and
brush wear
x Complete diagnostics through the handheld programmer,
the built-in Status LED, and the optional 840 Spyglass
display
x Two fault outputs provide diagnostics to remotely
mounted displays
x Regenerative braking allows shorter stopping distances,
increases battery charge, and reduces motor heating
x Automatic braking when throttle is reduced provides a
compression braking feel and enhances safety
x Brake/Drive Interlock meets ISO stopping distance
requirements
x Ramp restraint feature provides automatic electronic
braking that restricts vehicle movement while in neutral
x Meets EEC fault detect requirements
x Linear cutback of motor drive current during overtemperature or under-voltage
x Linear cutback of regenerative braking current during
overvoltage
x High pedal disable (HPD) and static return to off (SRO)
interlocks prevent vehicle runaway at startup
x Internal and external watchdog circuits ensure proper
software operation
x Fully protected inputs and short-circuit protected output
drivers
The controller’s rugged IP53 housing 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:
x Interlock braking with load sensor to meet required
braking distance without unnecessary harsh braking at
light loads
x Maintenance monitor responds to preset vehicle
operating hours and drive hours as programmed by the
OEM
x Two hour meters—total KSI-on hours and traction
hours—and the associated maintenance timers are built
into the controller
x BDI calculations performed within controller
x Estimates motor temperature based on field resistance
and cuts back maximum speed if the motor is overheated
x Diagnostic checks for field open and field shorted faults
29
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.
Owner’s Manual and Service Guide – PC Series
COMPONENTSELECTRICAL
Your Pack Mule vehicle should be equipped with one of the
following Curtis motor controller models:
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.
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.
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 are
requested at the time of order. These parameters can be
reprogrammed in 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)
b)
c)
d)
e)
Acceleration Rate
Braking Rate
Deceleration Rate
Maximum Forward Speed
Maximum Reverse Speed
Acceleration Rate: The acceleration rate defines the time it
takes the controller to accelerate from 0% drive output to
100% 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 accel 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%
braking output (as defined by the corresponding modespecific 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
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 100%. 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 0% to 100%. The default
setting for this is 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
maintenance:
cleaning
procedure
for
routine
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 B+ 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 overtighten them.
Deceleration Rate: 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
Owner’s Manual and Service Guide – PC Series
30
COMPONENTSELECTRICAL
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 8
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 state-ofcharge, 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.
31
Owner’s Manual and Service Guide – PC Series
COMPONENTSELECTRICAL
Fault Codes and Troubleshooting Chart:
Owner’s Manual and Service Guide – PC Series
32
COMPONENTSELECTRICAL
Fault Codes and Troubleshooting Chart:
33
Owner’s Manual and Service Guide – PC Series
COMPONENTSELECTRICAL
B ATTERY D ISCHARGE I NDICATOR (BDI)
S PEED C ONTROL P EDAL The Curtis BDI (Figure 32 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.
The speed control pedal is a rugged assembly with IP66 throttle
sensor protection for reliable use in harsh industrial
environments.
Features include:
x Attractive, easy-toread, 8 character dot
matrix Liquid
x Crystal Display.
• 6 LEDs -five green
to indicate battery
state-of-charge and
one red to indicate
that a fault has
occurred.
• Displays hours of
use, battery state-ofcharge
and
messages from the
F IGURE 32
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.
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.
BDI Connector Pin-Out
Pin Number
1
2
3
4
5
6
7
8
Function
N.C.
N.C.
B+ = 24V
B+ = 36V
Power In +
Receive
N.C.
Power In –
COMPONENTSELECTRICAL
S OLENOID 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 34
The BDI in 48 volt vehicles will display battery state-of-charge
and operating/ Traction hours only. Figure 33:
F IGURE 33
F IGURE 34
Owner’s Manual and Service Guide – PC Series
34
A
BDI
Yellow
F
Red
White
Red
Purple
Red
Red
36V
Battery
1
3
S1
Black
4
B-
2
Black
S2
8
16
Motor
B+
9
1
Rear Brake Light
Switch
Solenoid
+
-
Black
10 Amp Fuse
Blue
Black
Red
Red with White Stripe
Back-up
Alarm
Red
Red
1 Amp Fuse
Circuit Breaker
150 Amps/42Volt DC
Blue
White
Red
Red with White Stripe
Red
Red
-
+
Black
Orange
REVERSE
B NEGATIVE
KEY SWITCH
THROTTLE LO
THROTTLE HI
Charger
Foot Switch
Red with Yellow
Stripe
Curtis Controller
M-
LED Rear
Brake Light
Red
Red
Red
ON
Optional
Head Light Switch
OFF
Black
Red
Black with White Stripe
Purple
Blue
Directional
Switch
SEAT SWITCH
FORWARD
Orange
THROTTLE WIPER
Horn
FOOT SWITCH
BRAKE LIGHT
HEAD LIGHT
Brown
Yellow
Red with White Stripe
Red with Yellow Stripe
Yellow with Red Stripe
White
Optional
Parking
Brake Switch
Yellow with Red Stripe
Black
Optional
LED Head Light
F2
Circuit Diagram for Wesley
International Pack Mule, Including
Options (No 12V Power Supply). 2436V Sit Down. Curtis Controller Part
Number EV-E189.
INTERLOCK
1
5
Red
Black
Brown
Black
F1
Released June 20, 2012
Optional
Seat Switch
E
A2
Red
Black
A1
Red
Red
Key Switch
8
4
-
D
+
Horn
C
10 GAUGE WIRE
18 GAUGE WIRE
THROTTLE
B
ON OFF
06 GAUGE WIRE
REV FWD
Black
Horn Switch
Black with White Stripe
Black
Red
COMPONENTSELECTRICAL
P ARTS L IST – E LECTRICAL Part
Key Switch, 3-position (standard)
Key Replacement, set of 2
Directional Switch, 3 position Rocker
Horn
Horn Button
BDI – 24 / 36 volt vehicles
BDI – 48 volt vehicles
Solenoid, 4-terminal 36V
Solenoid, 4-terminal 48V
10 Amp Fuse
Fuse Holder
Charger Receptacle
Charger Cord
Onboard Battery Charger, 24 volt
Onboard Battery Charger, 36 volt
Onboard Battery Charger, 48 volt
Motor Controller, DC, 24 / 36 volt
Motor Controller, DC, 48 volt
Motor Controller, AC, 36 volt
Motor, DC
Motor, AC
Speed Control Pedal Assembly
Directional Switch, 3 position Toggle
Seat Presence Sensor Switch
Part Number
EV-E100
EV-E160
EV-E156
EV-E130
EV-E041
EV-E241
EV-E241-802
EV-E064HD
EV-E204 HD
EV-E015
EV-E016
EV-E027
EV-E026
EV-E801-24
EV-E801-36
EV-E801-48
EV-E189
EV-E189-48
EV-E181
EV-D040-S
EV-E185
EV-E
EV-E035
EV-E528
Owner’s Manual and Service Guide – PC Series
Part
Perma-Key Switch
Part Number
EV-E194PK
On/Off Switch
Programmable Code Security Switch
EV-E017
EV-E901
Headlight/Taillight Switch, Rocker
Single LED Charge Status Plate
EV-E155
EV-E808L
Foot Presence Switch
Battery Watering System – 24V GC135
EV-E128
EV-E900-6
Battery Watering System – 24V GC145
Battery Watering System – 36V GC135
Battery Watering System – 36V GC145
EV-E900-7
EV-E900-2
EV-E900-1
Battery Watering System – 48V FS8D
Headlight/Taillight – 24 / 36 volt
EV-E900FX-310
EV-E210-S
Headlight/Taillight – 48 volt
Headlight/Taillight/Brake light – 24 / 36 volt
Headlight/Taillight/Brake light – 48 volt
Flashing Safety Beacon – Amber
EV-E210-48-S
EV-E191
EV-E191-48
EV-E183
Flashing Safety Beacon – Blue
Flashing Safety Beacon – Red
Back-up Alarm
EV-E182B
EV-E182R
EV-E159A
Proximity Alarm
Curtis AC/DC Program/Diagnostic Handset
EV-E149
EV-E180
Hitch, Spring-Loaded Clevis, 1” pin
Hitch, Spring-Loaded Clevis, 5/8” pin
EV-F130H
EV-F178H
Hitch, Pin
Hitch, Pintle
EV-F134P
EV-F092
Hitch, Eye 2-3/8”
Hitch, Auto Coupling
Hitch, 3-Tier Assembly with Pin
EV-F132
EV-F133H
EV-F134
P ARTS L IST – A VAILABLE O PTIONS 36
F List for Front Wheel Steering Assembly
Parts
Front Wheel Assembly
#
37
Description
Part #
Qty
EV-W016
1
EV-W016-PC
1
EV-W016-PMT
1
Dual Front Wheel Axle, 1˝ X 18˝
EV-W017
1
Sleeve
EV-W007
2
EV-W007L
2
1
Dual Fork Assembly
1
Dual Fork Assembly, for PC series units
(Not Shown)
1
Dual Fork Assembly, for PMT series
units (Not Shown)
2
3
3
Sleeve, for PMT series/Wide Tire units
(Not Shown)
4
Spacer
EV-W014
2
4
Spacer, for PMT series/Wide Tire units
(Not Shown)
EV-W011
2
5
1˝ Flat Washer
EV-W027
6
6
1˝ Lock Washer
EV-W026
2
7
1˝ Slotted Hex Nut
EV-W006
4
8
Hub with 4 Studs
EV-W001
2
8
Hub with 5 Studs
EV-W034
2
9
Race, Bearing
EV-W010
6
10
Tapered Roller Bearing
EV-W009
6
11
Bushing, 1˝ X 1.25˝ X 0.625˝
EV-W011
1
12
Bushing, 1˝ X 1.25˝ X 0.5˝
EV-W011-S
1
13
Seal, Oil
EV-W008
6
14
1˝ Thin Slotted Hex Nut
EV-W013
1
15
Pin, Cotter 3/16˝ – 1 1/4˝
EV-W025
1
16
Lug Nuts
EV-W023
4 or 5
Owner’s Manual and Service Guide – PC Series
Transaxle Diagram for PC Series
Owner's Manual and Service Guide - PC Series
38
T
Transaxle
Parts List for PC Series
Pack Mule Transaxle Parts List
#
3
4
5
6
7
8
9
10
11
12
13
15
16
17
18
19
23
23
24
24
25
25
25
26
28
29
30
31, 32, 33
34
Kit
Part
Gear, Input
Ring, Retaining
O-Ring
Bearing, Ball
Bearing, Ball
Plug, End Cap
Bearing, Ball
Gear, Intermediate Assembly
O-Ring
Gear, Final Drive
Bearing, Ball
Screw, Cap
Nut, Lock
Plate, Cover
Plug, Fill
Screw, Cover Plate
Brake Assembly, Left Hand Shoe Type
Brake Assembly, Left Hand Shoe Type (Stock Chaser)
Brake Assembly, Right Hand Shoe Type
Brake Assembly, Right Hand Shoe Type (Stock Chaser)
Shaft, Axle 29˝ Left Hand (15 1/4˝ length)
Shaft, Axle 32˝ Left Hand (18 1/8˝ length)
Shaft, Axle 36˝ Left Hand (23 1/4˝ length)
Shaft, Axle Right Hand
Seal, Oil
Ring, Retaining
Bearing, Ball
Hub and Drum – 4-lug assembly with studs
Nut, Flange Hex
Kit, Gear Set (Includes #3, #10, #12)
Part Number
See Kit
EV-T016
EV-T014
EV-T015
EV-T013
EV-T017
EV-T011
See Kit
EV-T010
See Kit
EV-T008
EV-T006
EV-T007
EV-T018
EV-T020
EV-T021
EV-T054
EV-T054-S
EV-T055
EV-T055-S
EV-T023-29
EV-T023-32
EV-T023-36
EV-T025
EV-T030
EV-T029
EV-T028
EV-T058
EV-T064
EV-T065
QTY
1
3
3
1
1
2
2
1
2
2
4
4
1
1
10
1
1
1
1
1
1
1
1
2
4
2
2
2
1
EUV Owner’s Manual 2 May 22, 2009
39
19
Owner's Manuak and Service Guide - PC Series
T
Transaxle
Diagram for PCT Series
Power Mule Tugger Transaxle Assembly
EUV Owner’s Manual 2 May 22, 2009
Owner's Manual and Service Guide - PC Series
20
40
T
Transaxle Parts List for PCT Series
Power Mule Tugger Transaxle Parts List
#
3
4
5
6
7
8
9
10
11
12
13
15
16
17
18
19
23
23
24
24
25
26
27
28
29
30
31
31
32
Kit
37
Part
Gear, Input
Retaining, Ring
O-Ring
Bearing, Ball
Bearing, Ball
Plug, End Cap
Bearing, Ball
Gear, Intermediate Assembly
O-Ring
Gear, Final Drive
Bearing, Ball
Screw, Cap
Nut, Lock
Plate, Cover
Plug, Fill
Screw, Cover Plate
Brake Assembly, Left Hand Shoe Type
Brake Assembly, Left Hand Shoe Type (Stock Chaser)
Brake Assembly, Right Hand Shoe Type
Brake Assembly, Right Hand Shoe Type (Stock Chaser)
Seal, Oil
Ring, Retaining
Ring, Retaining, Wheel Bearing
Ring, Retaining
Bearing, Ball
Drum, Brake (5 lug)
Shaft, Left Hand Axle 32˝
Shaft, Left Hand Axle 36˝
Shaft, Right Hand Axle
Kit, Gear Set (Input, Intermediate Assembly, Final Drive)
Drum Assembly (5 lug)
Part Number
See Kit
EV-T016
EV-T014
EV-T015
EV-T013
EV-T017
EV-T011
See Kit
EV-T010
See Kit
EV-T008
EV-T006
EV-T007
EV-T018
EV-T020
EV-T021
EV-T054
EV-T054-S
EV-T055
EV-T055-S
EV-T076
EV-T077
EV-T078
EV-T079
EV-T080
EV-T075
EV-T081-32
EV-T081-36
EV-T082
EV-T083
EV-T075
QTY
1
3
3
1
1
2
2
1
2
1
2
4
4
1
1
10
1
1
1
1
2
2
2
4
2
2
1
1
1
1
1
EUV Owner’s Manual 2 May 22, 2009
41
21
Owner's Manuak and Service Guide - PC Series
PROUDLYBUILTINTHEUSA
Owner’s Manual and Service Guide – PC Series
38
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