Pack Mule PC NXG, PCT NXG Series Manual

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INDUSTRIAL ELECTRIC VEHICLE

April 2017

PC NXG and PCT NXG Series

Introduction

Thank you for choosing a Pack Mule Industrial Electric Vehicle, proudly built in the USA by Wesley International. Wesley International is committed to providing you with the best quality product and backing it with 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. For convenience, record your product information in the space below and keep this information with the vehicle. The model and serial numbers can be found on the vehicle identiﬁcation plate attached to the side of the motor compartment. See page 5 for the location of the vehicle identiﬁcation plate.

Record Your Product Information

Model #:

Serial #:

Purchase Date:

Registration is easy. Just go to http://www.packmule.com/mule-owners/register-a-mule/, complete the online form, and click submit.

If You Need Help

You will ﬁnd many answers in this manual or online at www.packmule.com. If you don’t ﬁnd what you need, just email us at info@wesleyintl.com or call (800) 241-2869 or (404) 292-7441. We’re always glad to help.

Important

Product registration is required for warranty coverage.

Phone (404) 292-7441 • Toll Free (800) 241-2869 • Fax (404) 292-8469

info@wesleyintl.com • www.wesleyinternational.com

Wesley International

3680 Chestnut Street

Scottdale, GA 30079

iii

Contents

Safety Information.........................................................................................................3

Training ................................................................................................................................................3

Operator Qualiﬁcations ...........................................................................................................................3

Safety Guidelines ....................................................................................................................................... 3

Loading and Unloading ............................................................................................................................3

Ventilation ................................................................................................................................................4

Towing ................................................................................................................................................4

Maintenance ............................................................................................................................................... 4

Operating Instructions .................................................................................................5

Before Putting Your Vehicle in Service .................................................................................................5

Vehicle Identiﬁcation ................................................................................................................................ 5

Charging Batteries ....................................................................................................................................5

Vehicle Controls, Meters, Switches ....................................................................................................... 5

Horn ................................................................................................................................................6

Accelerator/Brake ....................................................................................................................................6

Left-foot Presence Switch ......................................................................................................................6

Optional Equipment .................................................................................................................................6

The Smart View Display ...........................................................................................................................6

Driving the Pack Mule NXG ..................................................................................................................... 7

Parking ................................................................................................................................................ 7

Driver Assist on Inclines ........................................................................................................................... 7

Start-up Checklist .....................................................................................................................................8

Maintenance Schedule.............................................................................................................................9

Maintenance Instructions ..........................................................................................10

Routine Maintenance .............................................................................................................................10

Batteries ..............................................................................................................................................10

Battery Care .............................................................................................................................................. 11

Electrolyte Levels .................................................................................................................................... 11

Optional Battery Watering System ...................................................................................................... 11

Cleaning Batteries ................................................................................................................................... 11

Battery Replacement .............................................................................................................................. 11

Connecting the Batteries ....................................................................................................................... 11

Lifting the Vehicle....................................................................................................................................12

Tires and Wheels ..................................................................................................................................... 12

Brakes .............................................................................................................................................. 12

Electrical Components .......................................................................................................................... 13

Appendices ...................................................................................................................27

Appendix A: Industry Standards .............................................................................................................27

Appendix B: Programming the Safe-T-Lock Switch ..........................................................................32

Appendix C: Speciﬁcations......................................................................................................................34

Appendix D: Components—Electrical ..................................................................................................35

Appendix D: Components—Electrical (cont.) .....................................................................................36

Appendix E: Rear End ...............................................................................................................................37

Appendix F: Front Axle .............................................................................................................................38

Appendix G: Floor Panel ..........................................................................................................................39

Appendix H: Transaxle—SC Series ........................................................................................................ 40

Appendix I: Transaxle—SCT Series .........................................................................................................42

Please read this ﬁrst:

When you receive your Pack Mule NXG vehicle, it’s important to visually inspect the machine for any damage that may have occurred during shipping. If you ﬁnd any shipping damage, have it noted on the carrier’s bill immediately, speciﬁcally identifying the nature of the damage.

Keep this manual with the vehicle at all times. It provides operating and maintenance instructions, as well as precautions for the safe operation of the vehicle. It is the responsibility of the owner, user, lessor or lessees to ensure that the vehicle is used as intended.

Please read this entire manual to familiarize yourself with the safe operation of this vehicle, paying particular attention to anything labeled Caution, Note, or Warning. See below for the graphic representation of these. We also encourage you to read the industry standard operating and safety procedures in Appendix A.

Because of continuing product improvement, changes or updates may be made to this manual, making it subject to change without notice. For the most up-to-date version of the manual, go to the Pack Mule website (http://www.packmule.com/support/product-manuals) or call Wesley International at 1-800-241-2869.

The Pack Mule Division of Wesley International reserves the right to incorporate engineering and design changes to products in this manual without any obligation to include these changes on any units or vehicles already purchased or leased.

The Pack Mule Division and/or Wesley International accepts no liability in connection with any errors or omissions in this manual and speciﬁcally disclaims any liability for any incidental and consequential damages arising from the use of information in this manual.

The use of non-OEM (Original Equipment Manufacturer) parts may void the warranty.

Overﬁlling the batteries may void the warranties.

Notes, Cautions, and Warnings

Throughout this manual important information will be emphasized under one of the following headings. Please pay special attention to this information.

This graphic indicates information regarding a condition that should be observed.

This graphic indicates information regarding a condition that might result in damage to the vehicle.

This graphic indicates information regarding a condition that might result in severe injury or death.

Your Pack Mule PC NXG or PCT NXG Vehicle

Your Pack Mule NXG vehicle is powered by the industry-leading AC-Power system and has been conﬁgured and outﬁtted according to your company’s requirements. It is also available in dierent models, each designed to meet speciﬁc requirements. This manual covers the basics of each of the PC NXG or PCT NXG systems; however, you may ﬁnd dierences in the details shown here and your vehicle

The graphic below (Figure 1) provides an overview of the vehicle, as well as references to the pages in this document dealing with each of the parts.

Cargo Deck

The cargo capacity for each model can be found in Appendix C in the back of this manual.

Motor Compartments

Beneath the removable cargo deck are the motor (p. 15), the charger (p. 13) and the motor controller (p. 15).

Instrument Panel

On/O Switch, Forward/Reverse Control, and Smart View Display (p. 5)

The batteries (p. 10) are located under the seat. To access the batteries, grasp the seat back and tilt it forward.

Figure 1

Safety Information

This manual has been designed to help the owner/ operator operate the vehicle safely and according to the procedures and standards for which the vehicle was designed and intended for use. This section provides the essentials of safe operation. There is a more thorough discussion in Appendix A: Industry Standards.

Training

Vehicle owners are responsible for making certain that appropriate personnel are fully trained in the safe operation of the vehicle and understand its characteristics and features, the operation of its controls, and safe driving practices. Those responsible for training operators should ﬁrst become familiar with the conditions of the place where the vehicle will be operated in order to assess its eect on safe operation. Training should occur under the conditions of the operating environment while adhering to the safety guidelines and should include:

• Safety guidelines

• Safely operating vehicle in the work environment.

• Operation of all controls

• Safe driving practices

• A driving and operating test

Operator Qualiﬁcations

Operators should be selected based on their ability to safely operate the vehicle, including vision, hearing, physical and mental capabilities. Operators must:

• Demonstrate a working knowledge of all controls

• Understand all safety guidelines

• Be able to properly drive and park the vehicle under usual working conditions

• Know how to properly load, unload and tow cargo

• Recognize maintenance problems

Safety Guidelines

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 for safe vehicle operation:

• Read this manual before operating the vehicle

• Read, understand and observe all labels axed to the vehicle

• Do not operate vehicle without ﬁrst checking the

brakes

• 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 control while operating the vehicle

• Accelerate and decelerate slowly and in a controlled manner

• Always reduce speed when operating on poor terrain or in poor conditions

• Always maintain adequate distance between the vehicles, and 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 load or towing capacity

On grades, it is possible for vehicles to coast at greater than normal speeds. 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 atten-

tion to the CAUTIONS, SAFETY INFORMATION, and WARNINGS.

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.

Loading and Unloading

Follow these guidelines when loading and unloading cargo:

• Turn the vehicle o while loading or unloading

• Do not exceed the maximum cargo capacity

• Carefully and evenly position all loads

• Secure cargo so that nothing can easily fall o of the vehicle

• Be extremely careful when carrying loads that extend beyond the vehicle’s deck

Use a dedicated circuit for each battery charger and do not plug other appliances into receptacles on the circuit while the batteries are charging.

Towing

Follow these guidelines when towing:

• Turn the vehicle o and place directional selector in the center (neutral) position before attaching load to hitch.

• Ensure hitch is properly installed and secured (If the vehicle does not have a factory-installed hitch, the hitch is available from Wesley International.)

• Do not exceed the maximum towing capacity (The model’s towing capacity is on the Vehicle Identiﬁcation plate (Figure 2) and in Appendix C of this manual.)

• Do not exceed 5 mph when towing

• Take extreme care when towing down an incline

• Avoid sudden stops since the stop may cause the trailer to jackknife

• Keep in mind that heavy loads being towed may signiﬁcantly increase stopping distances

Maintenance

Always maintain your vehicle in accordance with the service schedule in this manual and keep complete records of the maintenance history of the vehicle. Ensure that maintenance personnel performing any service or repair work on the vehicle are properly trained and qualiﬁed. When performing any maintenance on the vehicle, disable the vehicle by removing the key from the key switch and disconnecting the battery cable.

Untrained or unauthorized personnel should never attempt to perform service or maintenance on the vehicle. Improper maintenance can cause hazardous conditions. Contact Wesley International for authorized service assistance.

Always use insulated tools when working in the battery area. Improper tools may cause sparks or an explosion. Wear approved safety goggles or face shield.

The electrolyte in a lead acid battery is an acid solution which can cause severe burns to the body and eyes. Treat all spills to the body and eyes with extended ﬂushing with clear water; then contact a physician immediately.

Electrolyte spills will corrode the vehicle’s frame and body if not treated immediately. Wear proper protective clothing, gloves and eye wear. Thoroughly clean all areas with a neutralizing solution of ¼-cup (60 mL) sodium bicarbonate (baking soda) dissolved in 1½ gallons (6 L) of water.

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 (p. 12).

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 void the warranty.

Ventilation

When performing any maintenance on the Pack Mule PC NXG or PCT NXG or charging the batteries, make sure that you are in a well-ventilated area. Hydrogen gas is generated in the charging cycle and is explosive in concentrations as low as 4%. Five air exchanges per hour is considered the minimum ventilation required.

Be sure to check the polarity of each battery terminal and rewire the batteries according to the schematic shown in this manual (p. 11, Figure 14). 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.

The battery charging cycle may generate highly explosive hydrogen gas. Make certain that the charging is done in a well ventilated area and is away from anything that might create sparks.

Operating Instructions

Before Putting Your Vehicle in Service

• Check for leaking ﬂuids (brake ﬂuid, battery acid, or transaxle oil).

• Check condition of tires for defects or damage. If your vehicle is equipped with pneumatic tires, make certain that they are properly inﬂated.

• Check to ensure that wheel lugs are tight.

• Check to ensure that battery cables are tight and batteries are secure.

• Check the steering, brake, and electrical controls for proper operation.

• Charge the batteries.

Vehicle Identiﬁcation

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. Connect only one charger to a single 15A circuit or the circuit may become overloaded.

Figure 3: The AC cord for charging the batteries. Simply extend the cord and plug it in to an appropriate receptacle.

Figure 4: The LED display on top of the charger indicates when the battery is completely charged. For a complete list of LED messages, see page 17.

Vehicle Controls, Meters, Switches

All of the controls are located on the panel in front

of the operator. They are:

Figure 2: The Vehicle Identiﬁcation Plate is located on the inside of the motor compartment. Please refer to this information when requesting warranty service, ordering replacement parts, or requesting service support from Wesley International.

Charging Batteries

The Onboard High Frequency Charger is standard on the Pack Mule NXG. To charge the vehicle’s batteries, do the following:

• Position the vehicle in a well ventilated area within six feet of the charging outlet.

• Connect the vehicle’s AC cord (Figure 3) to the outlet.

• Conﬁrm the charging status on the LED display on the charger. (Figure 4)

If the vehicle has the optional Single-LED display, located near the key switch, it will display a solid green light when the batteries are fully charged.

• The On/O switch. The rocker switch (shown below) is standard, but your vehicle may be equipped with a key switch, a Safe-T-Lock keypad or Perma-Key switch. The Perma-Key switch is similar to the standard key switch except that once the key is inserted, it cannot be removed.

• The FWD/NEUTRAL/REV directional selector switch.

• The Smart View Display (See page 6 for display information.)

Figure 5: The instrument panel showing (1) the on/o switch, (2) the directional selector switch, and (3) the Smart View display.

The FWD/REV directional selector switch is a three-position rocker switch. Press the top section down for Forward and the bottom for Reverse. When neither the top nor bottom position is selected, the vehicle is in neutral. Always place the directional switch in neutral when the vehicle is parked or stationary or when leaving the vehicle.

The static return-to-o feature prevents the vehicle from starting with a direction selected. To start the vehicle, put the switch in the neutral position and turn the key on.

The Smart View Display

The Smart View display communicates directly with the onboard controller and displays important vehicle information when the key is switched on:

• Battery State of Charge (Displayed as a percentage of charge remaining.)

• Traction Hours (the time the switch is on)

• System Fault Code (See page 17 for an explanation of the fault codes.)

Figure 7: The Accelerator/Brake Pedal. With the key switch turned to “On”, and the directional switch at “Forward” or “Reverse, the pedal puts the vehicle in motion. When the pedal is released, the vehicle stops. .

Presence Switch

The standard seat presence switch ensures that the operator is properly positioned in before the vehicle is put into motion. The vehicle may also be equipped with a left-foot presence switch. To move the vehicle either forward or backward, the operator must depress the switch. When the switch is released, the vehicle stops.

When clearing a fault, make sure that you do not have the left-foot presence switch engaged. The fault will not clear when the switch is engaged.

Optional Equipment

Your Pack Mule NXG may be equipped with any of the following optional equipment:

Headlights/Tail Lights: These are controlled by a rocker switch located near the directional control.

Horn

The horn, located on the ﬂoor at the operator’s left foot or (optionally) on the side of the panel, sounds when you press the horn button. It will not sound when the key switch is in the “o” position.

Accelerator/Brake

The pedal (Figure 7) located at the operator’s right foot controls the travel speed of the vehicle, releasing the pedal activates some regenerative braking. Additional mechanical and regenerative braking is engaged using the brake pedal. Drive is inhibited when the brake pedal is depressed. The speed increases as the pedal is depressed, up to the limits set in the controller.

Parking Brake: The vehicle may have an electronic or hand parking brake instead of the parking brake pedal. The electronic brake is automatically engaged when the motor stops.

Programmable Security Switch: Your vehicle may be equipped with the optional “SAFE-T-LOCK. The programmable switch prevents the unauthorized use of the vehicle and allows up to 99 authorized users. Instructions for programming the switch are found in Appendix B.

Tow Hitch: A manufacturer-approved tow hitch is required for towing a trailer. If the vehicle does not have the optional factory-installed tow hitch, hitches matching the vehicle’s tow ability are available from Pack Mule.

Figure 8: The optional parking brake in the OFF position. Parking brake tension may be adjusted by turning the knob at the end of the handle (indicated by the arrow)..

Excessive brake tension will cause cable wear and

may cause brake failure.

The Back-up or Proximity Alarm: The back-up

alarm sounds continuously when the direction selector switch is set to reverse. The proximity alarm sounds continuously when the direction selector switch is set to either forward or reverse.

7. Engage the left-foot presence switch (if present) with the left foot.

8. Gradually press the accelerator pedal. The speed of the vehicle, up to the limit set by the controller, is determined by the amount of pedal travel.

9. To stop, remove your foot from the accelerator/ brake pedal.

Parking

• Set the directional switch to the neutral position.

• Set the key switch or rocker switch to “O.”

• Apply the parking brake and depress the brake pedal as needed.

• If parking on an incline, turn the front wheels into the curb to prevent accidental movement.

Driving the Pack Mule NXG

The Pack Mule vehicle is designed to be simple to use. However, for safe operation, the operator must practice appropriate operating techniques, as outlined below. This list assumes that the daily maintenance schedule (p. 8) has been followed.

1. Make certain that the battery charger AC cord is unplugged and properly stored. The vehicle control is interlocked so that the vehicle will not move when the on-board charger is plugged in.

2. Check the surrounding area to make sure that it is clear of obstruction and make certain that the cargo is properly loaded and secured.

3. Make sure that you are properly positioned in the . Your right foot will operate the accelerator/ brake pedal and your left foot will activate the foot presence switch (if present). Move the directional switch to the neutral position.

4. Turn the vehicle on by turning the O/On switch to the “On” position.

5. Check the BDI display for the battery and system status.

6. Set the directional switch to the desired direction. If the accelarator is depressed while the directional switch is set to “Neutral,” the Smart View Display will show a fault. To clear the fault, turn the O/On switch to O, then back on. Set the directional switch to desired direction.

Uphill

Figure 9: Proper positioning of the Pack Mule’s front wheels when parking on an incline.

Driver Assist on Inclines

Unlike other electric utility vehicles, the Pack Mule NXG has a controller that seamlessly applies the regenerative brakes to limit speeds on descending inclines and provides additional power as needed on ascending inclines.

Although the Pack Mule NXG provides automatic regenerative braking on inclines, operators should be alert to vehicle and load instability on unlevel surfaces.

Start-up Checklist

Below is a sample checklist of tasks to be performed each day before the vehicle is put into service. It covers

the daily maintenance in the maintenance list found on the next page.

Truck No. ___________________________________ Operator ____________________________ Date __________

Visual OK Fix

Obvious Damage

Cracked Frame Welds

Model Tag Readable

Tires Properly Inﬂated and Cut Free

Fluid Leaks

Charging Cord Unplugged

Wire Insulation Undamaged

Battery Connections Clean and Secure

Battery Water Level

Steering

Brakes

Horn (Switch must be turned on.)

Battery Discharge Indicator

Comments:

Switch in OFF position if leaving vehicle

To prevent unexpected movement on start-up, make certain that the directional switch is in the NEUTRAL (center) position when leaving the vehicle.

After completing the inspection, the operator should turn the form in to the supervisor, who should keep the form on ﬁle for thirty days.

Maintenance Schedule

The Pack Mule NXG vehicle is virtually maintenance free in its standard conﬁguration. It has a sealed AC motor with no brushes to be replaced, and the transaxle is sealed and does not require periodic lubrication. The list belows what should be done monthly, Bi-Annually (or at 125 hours of operation) , and Annually (or at 250 hours of operation). Operating hours are shown on the display on the instrument panel.

Bi-

Service

1. Check operation of all gauges, horn, and lights.

2. Check BDI for battery state of charge.

Monthly

Annual Annual

P P P

3. Charge batteries when vehicle is not in service. Charge overnight up to 8 hours.

4. Check tires for cuts, excessive wear, and cold pressure.

P P P

5. Check wheels for bent rims, missing or loose lug nuts.

6. Check battery for correct electrolyte level.

7. Check for loose steering. Adjust as required.

8. Clean batteries and terminals with a solution of ¼ cup (60 mL) baking soda to 1½ gallon of water. Tighten terminals and coat with anti-corrosion compound.

9. Inspect brake system linkages, brake linings and other components for wear and adjustment.

10. Check speciﬁc gravity of all battery cells using hydrometer.

Notes:

1. In freezing temperatures recharge the batteries after adding distilled water to make sure that the water mixes with the electrolyte properly. Otherwise the water may freeze and damage the batteries.

2. Pneumatic tire recommended tire pressure is 60 psi for LRB tires and 90 psi for LRC tires. Improper tire inﬂation may reduce tire life and adversely aect vehicle handling. It may also lead to sudden tire failure, resulting in a loss of vehicle control.

3. A hydrometer, measuring the speciﬁc gravity of the electrolyte, is used to determine if a battery is properly charged. With a fully charged battery, the reading should be about 1.260; fully discharged it should be about

1.100.

4. The transaxle is sealed and does not require routine maintenance.

P P P

P P

Maintenance Instructions

Routine Maintenance

Before performing any maintenance or repair work on the vehicle, isolate the batteries from the motor and electronics by removing the 10-amp fuse. (Figure

10) When ﬁnished, replace the fuse .

Figure 10: The fuse (indicated by the arrow) should be removed before performing any maintenance or repair work on the electrical system.

Batteries

The standard batteries used in the Pack Mule are lead acid, 6-volt, deep cycle, golf-cart style. Other battery types are available.

Always observe the following warnings when

working on or near batteries:

Keep all smoking materials, open ﬂames, or sparks away from batteries. Any ﬂame or spark might cause an explosion.

Do not charge batteries in areas without adequate ventilation. Small concentrations of hydrogen gas are enough to cause an explosion.

Make sure that the key or rocker switch is in the “O” position, all electrical accessories are o, and the circuit breaker is in the open position (Figure 12) before working on the vehicle.

The electrolyte in a lead acid battery is an acid solution that can cause severe burns to the skin and eyes. If you come into contact with the electrolyte, ﬂush the area with plenty of clear water and contact a physician immediately.

Always use properly insulated tools when working on electric vehicles. Properly insulated tools will help to prevent electrical shock that can result in equipment damage, severe personal injury or even death.

Figure 11: The major components of the electrical system. They are (1) motor, (2) controller, (3) coil (with fuse) and (4) batteries.

Battery Care

The useful life of the batteries installed in the Pack Mule NXG vehicle will be longer if they are properly cared for. Keep the following in mind:

• Place battery into service and complete a full discharge and charge cycle. Check the electrolyte level, and add approved water (never acid) if needed after this ﬁrst cycle is completed.

• Never discharge the battery beyond 80%, and do not use the battery if the speciﬁc gravity falls below 1.150.

• During shipment or prolonged storage, the electrolyte levels may fall below the separator protector. Keep electrolyte levels above the separator and /” (3.175mm) below the vent well. Water batteries only as required and after a complete charge and discharge cycle.

• Use only distilled or purified water, free of contaminants. (Contaminants in water may reduce the chemical reaction causing a reduction in battery life.)

• Be sure to replace the vent caps after watering to prevent electrolyte from spilling out.

• Keep the battery top clean and dry, and the vent caps tightly sealed.

• Keep open flame and metal objects away from the battery top.

• Keep the battery compartment open and well ventilated during the charging cycle.

• Charge batteries after each day’s use.

gallons (6 L) of water. Apply the solution to the top and sides of the batteries and allow the solution to sit for three minutes. Thoroughly rinse the area with low-pressure, clear water.

Battery Replacement

Care should be taken in removing and replacing batteries. Each battery weighs approximately 70 pounds. Lifting the battery without using appropriate equipment may cause injury.

To remove the battery, remove the 10-amp fuse (Figure 10), remove the hold-down clamps and interconnected cables. Ensure that the battery ﬁll caps are securely attached. Then attach the lifting device and remove the battery.

Connecting the Batteries

All conﬁgurations (24 v, 36 v and 48 v) of the Pack Mule batteries are connected in series as shown in Figure 12. The red wire is connected to the battery positive input connection, the remainder of the batteries are connected negative to positive, and the black wire is attached to the last battery’s negative connection. According to the voltage, your vehicle may have eight batteries instead of six; however, the series connection is the same.

Electrolyte Levels

The electrolyte levels should be carefully monitored and maintained ½” (13mm) above the plates in each cell. If the electrolyte level is too low, the plates will be exposed to air and ruined beyond repair. If it is too high, the electrolyte will be forced out of the battery during the charge cycle.

Optional Battery Watering System

Pack Mule oers battery watering systems as an option for the Pack Mule NXG. This system provides a fast, accurate, and safe way to maintain precise battery electrolyte levels.

Cleaning Batteries

For ecient operation, the battery tops and terminals should be kept clean. The tops should be kept free of dirt and debris.

Clean the batteries using a solution speciﬁcally formulated to neutralize battery acid deposit or a solution of sodium bicarbonate (baking soda) and water. Mix ¼ cup (60 mL) of sodium bicarbonate with 1½

Figure 12: The batteries connected in series.

Vehicles with on-board chargers have a temperature sensor attached to the negative terminal to prevent overheating during recharge.

Always wear proper safety equipment, including safety goggles or a face shield when working around batteries.

To protect against personal injury or equipment damage, always use insulated tools when working on an electric vehicle

Lifting the Vehicle

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 in Figure 13 below 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.

• Soft Solid

• Solid Non-Marking (o-white)

Although all of these should be inspected periodically, only the pneumatic tires require maintenance. Make certain that the tire pressure is maintained at 60 psi for LRB tires and 90 psi for LRC tires.

Changing the vehicle’s tires is very much like changing an automobile tire. Follow the procedure below to change the tire safely.

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.

The vehicle may be lifted with an overhead crane and J-Hooks. The J-hooks should be attached to the frame at the four corners of the battery/engine compartment. The crane capacity should be greater than 1200 lbs (standard battery) or 1500 lbs (industrial battery). Do not work under the machine when hoisted by a crane.

1. Position the jack in the proper position (Figure

13)

2. Loosen the lug nuts on the wheel to be changed.

3. Raise the jack until the tire is clear of the surface.

4. Remove the tire.

To replace the tire, reverse the procedure, tightening the lug nuts to 70 to 80 ft. lbs. (95 to 108 Nm) torque.

Brakes

The vehicle is equipped with a pair of rear mechanical drum brakes which only engage for parking and/ or emergency stopping. Normal braking uses the regenerative braking controlled by the combination accelerator/brake pedal.

Mechanical brakes are adjusted by advancing the two nuts on the central rod until the slop disappears. Brake wear may cause the need for a repeat adjustment..

Figure 13: Position the jacks or jack stands

Do not lift the vehicle on unlevel or unstable surfaces. When lifting the vehicle to jack stands, always lift and secure the front of the vehicle ﬁrst. If the rear of the vehicle is lifted ﬁrst, the front may become unstable.

Tires and Wheels

Your Pack Mule vehicle may be equipped with any

one of the following types of tires:

• Pneumatic (standard)

• Solid

Figure 14: To adjust the mechanical drum brakes, advance the two nuts on the central rod (indicated by the arrow)..

Electrical Components

Onboard Battery Charger

Your Pack Mule NXG is equipped with an onboard Delta-Q Battery Charger. The charger is air-cooled with no moving parts, providing dependable charging with little maintenance. To assure continued trouble-free operation, you should be aware of the following:

Ammeter

• If solid: displays scale of output during bulk phase.

• If ﬂashing: Output has been reduced due to high internal charger temperature. Displays charge proﬁles 1-6 for 11 seconds if no battery is present.

Fault Indicator (Red Light)

• Charger error. Count the number of ﬂashes between pauses and refer to the troubleshooting information in the table below.

• The cooling ﬁns on the charger should be checked regularly, making sure that they are free of dirt, dust, and other contaminants.

• The charger is designed to operate in environments between -30°C (-22°F) to 50°C (122°F).

• Do not expose the charger to oil, mud, or heavy water spray when cleaning the vehicle.

Bulk Charge Indicator

• If solid: Bulk charge phase complete (80% charge); in absorption phase.

• If ﬂashing: Displays charge proﬁle number if no battery is connected.

Charge Completion Indicator (Green Light)

• If solid: Charging complete and maintenance mode is active.

• If ﬂashing: Absorption phase complete, in ﬁnishing phase.

AC Indicator

• If solid: AC power is present.

• If ﬂashing: Low AC voltage. Check electrical source and cord length.

Troubleshooting Instructions

If a fault occurs, count the number of ﬂashes between pauses and refer to the table below.

Flashes Cause Solution

1 Battery high voltage Check battery size and condition. This fault will clear automatically

once the condition has been corrected.

2 Battery low voltage Check battery size and condition. This fault will clear automatically

once the condition has been corrected.

3 Charge timeout caused by the

batter pack not reaching the required voltage or charge

4 Battery could not be trickle

charged up to minimum voltage.

5 Charger shutdown due to

high internal temperature

6 Internal charger fault Reset the charger by interrupting the AC for at least 15 seconds. If

Check connections, that battery type matches the selected charge proﬁle and operate the charger at a lower ambient temperature. Reset the charger by interrupting the AC for at least 15 seconds.

Check for shorted or damaged cells. Reset the charger by interrupting the AC for at least 15 seconds.

Ensure sucient cooling airﬂow. Reset the charger by interrupting the AC for at least 15 seconds.

fault persists, it is likely the charger will need to be replaced.

Onboard Battery Charger (continued)

If the detachable input power supply cord set is damaged, replace with a cord that is: (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 (for all other countries) a safety approved detachable cord, 3 conductor,

1.5mm² minimum, rated appropriately for industrial use. The cord set must be terminated 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.

Extension cords must be 3-wire cord no longer than 30m (100’) at 10AWG or 7.5m (25’) at 16AWG per UL guidelines.

Connect only one charger to a single 15A circuit or the circuit may become overloaded.

Charger enclosure may be hot during charging. Use hand protection if handling the charger while charging.

To prevent risk of electric shock, observe the fol-

lowing cautions:

Connect charger power cord to an outlet that has been properly installed and grounded in accordance with all local codes and ordinances. A grounded outlet is required to reduce risk of electric shock. Do not use ground adapters or modify the plug.

Do not touch uninsulated portion of output connector or uninsulated battery terminals. Disconnect the AC supply before making or breaking the connections to the battery.

Do not open or disassemble charger. Do not operate this charger if the AC supply cord is damaged or if the charger has received a sharp blow, been dropped, or otherwise damaged in any way. Refer all repair work to the manufacturer or qualiﬁed personnel.

This appliance is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety.

Optional Single LED Display

If the optional single-LED display is included, it will be located on the front panel, near the key switch.

Motor

Your Pack Mule NXG vehicle is equipped with an AC motor system. (Figure 15) This motor requires no periodic maintenance since it has no brushes to be replaced.

Figure 15: The motor connected to the Sevcon motor controller.

Motor Controller

There are no usable serviceable parts in the Sevcon motor controller. However, it is recommended that the controller be kept clean and dry to 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 cleaning procedure below for routine maintenance:

1. Remove power by disconnecting the battery.

2. Discharge the capacitors in the controller by connecting a load (such as a connector coil or a horn) across the 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.

No attempt should be made to open, repair, or otherwise modify the controller. Doing so may damage the controller and will void the warranty.

Programmable Parameters

Programmable parameters allow the vehicle’s performance characteristics to be customized to ﬁt the speciﬁc vehicle application or environment. Pack Mule vehicles are programmed with standard default parameter settings. The ﬁve parameters listed below have the most eect on vehicle behavior and can be adjusted with the available hand-held programmer.

• Acceleration Rate

• Deceleration Rate

• Throttle

• Maximum Forward Speed

• Maximum Reverse Speed

Acceleration Rate: 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.

Deceleration Rate: The time it takes the controller to reduce its output when the throttle is reduced or released. A lower value represents a faster deceleration and thus a shorter stopping distance.

Throttle Map: The control will match the vehicle speed according to the pedal depression up to the maximum speed programmed into the controller.

Maximum Forward Speed: The maximum forward speed parameter deﬁnes the maximum controller voltage output at full throttle in the forward direction.

Maximum Reverse Speed: The maximum reverse speed parameter deﬁnes the maximum controller voltage output at full throttle in the reverse direction.

The factory settings for these parameters are:

• Accelaration Rate: 1.6 seconds

• Decelaration Rate: 2.5 seconds

• Throttle Map: 50

• Maximum Forward Speed: 70 (approximately 7 mph)

• Maximum Reverse Speed: 35 (approximately 3.5 mph)

Diagnostics and Troubleshooting

The Pack Mule NXG vehicle has on-board diagnostics that facilitate troubleshooting. When the controller senses a fault, either when the vehicle is switched on or is operation, it shows a fault code. (Figure 18). If the Smartview Display is damaged or otherwise inoperable, the fault code can be read directly from the controller by counting the number of consecutive LED ﬂashes. The fault codes and LED codes are shown in the charts on pages 17 and 18.

There are ﬁve categories of faults. Below are the categories, the letter or letters identifying them in the table, and the action taken by the controller when sensing the fault.

1. Information (I) Information faults do not require

immediate action, although some cutback in power may occur.

2. Drive-inhibit (D) Neutral brakes or coasts the

traction motor to a stop. The fault prevents the operator initiating drive, but does not inhibit braking functions.

3. Severe (S) Immediate shut down of the sys-

tem.

4. Very Severe (VS) Immediate shut down of the

system.

5. Return to Base (RTB) Immediate shutdown of

the system.

Figure 18: The Smart View display indicating a fault.

1 2 3 4 5 6 7

Brake Light

Key Switch

Controller Fuse 10A

Electro Brake

48V

or 36V or 24V

E E

Horn P/Button

Line Contactor

Thermistor

Line Contactor

LC3 Supply

10V

Encoder A

Encoder B

Horn

LC1 Supply

Trac Fuse

B+

B-

+5 Volt

Analog 1 Throttle

Analog 2 FS1

Half Speed

Creep

Deadman Foot

Reverse

Forward

Hand Brake

+24V

Can High

Can Low

Can Terminator

Charger Cord

SmartView Display

ClearView Display

Brake Light SW

Seat Switch

B-

Dual Hall Effect Sensor

4K OHM

18V Zener

Run Light

Reverse Light

Beeper

B+

SEVCONsitWIRE WTS-1020.dwg

1 32 4 5 6 7

Figure 17: Typical Controller wiring conﬁguration.

Fault Codes and Troubleshooting Chart

LED

Code

5 5 5 5

5 F15005 1 Isolation fault detected between

5 5

5 6

6 6

Smart View

Fault Code

F12001 1 Handbrake is on when direction is

F15001* F15002* F15003* F15004*

F15006 1 No motor speed feedback from

F15007 1 Tow mode has been activated. Disable tow mode if not re-

F15008 1 Invalid steer sensor state Check steer sensor wiring F15009 1 Pulsed enable signal not present,

F15010 1 Unable to complete power-on

F15011 1 MOSFET/IGBT s/c tests at power

F15012 1 Battery electrolyte Low Level de-

F15013 1 Battery electrolyte Low Level de-

F15014* 1

F16001 1 Warning level throttle fault. Used

F16002 1 Throttle appears to be stuck. This

F16003 1 Throttle appears to be stuck. This

F16004 1 Contactor driver over current Ensure contactor doesn’t

F16005 1 Contactor driver not working Internal hardware fault. F16006 1 Contactor driver over temperature. Ensure contactor doesn’t

F16007 1 Contactor driver unable to achieve

F16008 1 Contactor driver MOSFET short

F16009 1 Analog supply is >10% out of

Fault

Category

Possible Cause Fault Clearance

selected.

logic and power frame.

motor.

unable to enable bridge.

checks to allow bridge to enable.

up are being held o.

tected

tected and cut back.

on Renault Twizy.

fault will clear if throttle starts to work again.

fault will latch and can only be cleared by repairing the throttle and recycling power.

current target in current mode

circuit dete

range.

Disengage handbrake.

Check isolation between low and high voltage circuits

Check encoder wiring and speed measurement signal.

quired.

Check 1kHz pulsed enable signal is received

Check motor connected or wait for motor to slow down.

Check battery electrolyte level

Check throttle wiring and installation.

exceed maximum current and check contact wiring

Ensure contactor driver current target is within range.

Internal hardware fault.

Fault Codes and Troubleshooting Chart (continued)

LED

Code

Smart View

Fault Code

F16009 1 Analogue supply is >10% out of range. Remove short. Check

F16010 1 Seat regen settings applied. Close the seat switch

F16011 1 Customer speciﬁc fault. Shown when

F17001 1 BDI remaining charge is less than BDI

F17002 1 BDI remaining charge is less than BDI

F17003 1 Battery voltage is less than Under Volt-

F17004 1 Battery voltage is greater than Over

F17005 1 Capacacitor voltage is greater than

F17006 1 Battery voltage is less than rated min-

F17007 1 Battery voltage is greater than rated

F17008 1 Capacitor voltage is greater than rated

F17009 1 Motor control has entered low voltage

F17010 1 Motor control has entered high volt-

F17011 1 Mains Under Voltage Check Mains Supply

Fault

Category

Possible Cause Fault Clearance

analogue footbrake voltage does not match digital footbrake switch state.

warning level.

Cutout level

age limit for longer than protection delay.

Voltage limit for longer than protection delay.

rated maximum voltage for longer than protection delay.

imum voltage for controller for longer than 1s.**

maximum voltage for longer than 1s.

cutback region.

age cutback region.

output voltage.

and recycle the direction to remove the seat regen settings.

Check footbrake wiring and installation.

Charge battery

7 8

**This fault is commonly seen at power down.

F17012 1 Mains Over Voltage Check Mains Supply

F17013 1 The voltage applied to the KL15/30 is

F17014 1 Vcap is NOT >7/8 Vkey Charge battery F18001 1 Low heatsink termperature has re-

below the controller

duced power to motor

Check KL15/30 supply voltage

Allow controller to warm up to normal operating temperature.

Fault Codes and Troubleshooting Chart (continued)

LED

Code

Smart View

Fault Code

F18002 1 High heatsink temperature has

F18003 1 High measured or estimated motor

F18004 1 Low measured temperature has

F10101 1 Controller is in pre-operational

F10102 1 Controller has not received all

F10103 1 One or more conﬁgured RPDOs

F11101 1 Encoder is not aligned properly. Ensure encoder oset is

F11102 1 SinCos Encoder Min Max values

F11103 1 A fault ride-through event has

F11104 1 The open loop V/f induction motor

F11105 1 Stator resistance thermal com-

F11106 1 Encoder PLL has turned o due to

F12101 1 Vehicle is operating in reducd

Fault

Category

Possible Cause Fault Clearance

reduced power to motor

temperature has reduced power to motor.

reached -30 degrees.

state.

conﬁgured RPDOs at power up.

not received within 3s of start up or 500 ms during normal operation

are heading towards a voltage rail or converging together.

been encounter, but operation is allowed to continue although the system may be derated.

software has detected a pulled-out condition (applied frequency much larger than actual). It will automatically attempt to restart.

pensation has failed due to the estimated value being too dierent from the conﬁgured value.

poor tracking.

power mode as some CAN messages are not being received. (Renault only)

Allow controller to cool down to normal operating temperature.

Allow motor to cool down to normal operating temperature.

Check motor thermistor connection or allow motor to warm up.

If conﬁgured and ready for use, change state to operational.

Check PDOs on all CANbus nodes are conﬁgured correctly and match up.

Check status of all nodes on CANbus. Check PDOs on all CANbus nodes are conﬁgured correctly and match up.

correctly set or re-align encoder

Thermal or mechanical variation is causing the sincos encoder to deviate from the cold factory commissioned values

None

Reduce load torque transients and demanded accelaration rates. Check motor parameters (V/f ratio and current limit/allowed torque may too low) and control gains.

Check the value of Rs conﬁgured in the controller is correct for the motor.

Check PLL gains and encoder setup and wiring.

Check status of nodes on CANbus expected to be transmitting data.

Fault Codes and Troubleshooting Chart (continued)

LED

Code

13 F13101 1 This warning is set if any task has

13 F13102 1 An internal logic supply rail has

14 F14101 1 EMCY message received from

14 F14102 1 14 F14103 1 15 F15101 1 Vehicle service next due time has

2 F22001 2 Valid direction selected with oper-

2 F22002 2 Both the forward and reverse

2 F22003 2 FS1 active for user conﬁgurable

2 F22004 2 Any drive switch active at power

2 F22005 2 FS1 active after a direction change

2 F22006 2 Inch switch active along with any

2 F22007 2 Vehicle overloaded Remove overload condition 2 F22008* 2 2 F22009* 2 2 F22010 2 Traction function inhibited using

2 F22011 2 Vehicle changed from traction

2 F22012* 2 2 F22013* 2 2 F22014 2 Fault with momentary direction

Smart View

Fault Code

Fault

Category

Possible Cause Fault Clearance

between 10% and 20% of its stack free

gone out of range.

non-Sevcon node and anonymous EMCY level is set to 1.

expired (if supported). If supported, service driveability proﬁle will activate.

ator not seated or operator is not seated for a user conﬁgurable time in driver.

switches have been inactive simultaneously for greater than 200 ms.

delay without a direction selected.

up.

and FS1 recycle function enabled.

drive switch active, seat switch indicating operator present or handbrake switch active.

traction inhibit switch.

mode to pump mode (or vice-versa) when direction selected.

selection switch.

Check status of nonSevcon nodes on CANbus.

Service vehicle and reset service hours counter.

Must be seated with switches inactive.

Check vehicle wiring and reset switches.

Deselect FS1.

Deselect all drive switches

Deselect FS1.

Deselect traction inhibit.

Deselect all drive switches.

Release momentary direction switch

Fault Codes and Troubleshooting Chart (continued)

LED

Code

2 F22015 2 Sensorless has failed to start up. 5 F25001*

5 F25002 2 An issue has occurred with the PST

6 F26001 2 Throttle value is greater than 20%

6 F26002 2 Wire-o detected in electrobrake

6 F26003 2 Direction is changed and vehicle

7 F27001 2 Measured ORFET voltage diers

7 F27002 2 Controller has entered thermal or

8 F28001 2 Thermal or voltage cutback factors

10 F20101 2 One or more conﬁgured RPDOs

12 F22101* 2 12 F22102* 2 12 F22103 2 Vehicle application subsystem is

12 F22104 2 Controller failed to receive re-

12 F22105 2 A message has been lost in the

12 F22106 2 A message has been lost in the

12 F22107 2 A signal in a message has been

12 F22108 2 A signal in a message has been

14 F24101 2 EMCY message received from

14 F24102 2 Boost enable state from hardware

14 F24103 2 Boost stage is above maximum

Smart View

Fault Code

Fault

Category

Possible Cause Fault Clearance

unit.

at power up.

circuit.

speed is greater than allowed.

too much from measured output voltage.

voltage cutback region.

have reduced below user-deﬁned levels.

not received within 3s at start up or 500ms during normal operation.

not receiving control or status information.

quired CAN messages.

CAN protocol.

invalid for 5 cycles.

non-Sevcon node and anonymous EMC level.

and processor comms does not match.

operating voltage.

Check PST Unit

Release throttle

Check electrobrake wiring, ensuring current ﬂows when energized.

Select neutral switch to clear the fault.

Check vehicle wiring.

Check for temperature or voltage cutback condition and take appropriate action.

Check status of all nodes on CANbus. Check PDOs on all CANbus nodes

Check CANbus wiring and conﬁguration of J1939 signal mapping.

Check CANbus wiring and CAN network.

Check CANbuswiring.

Check status of nonSevcon nodes on CANbus.

Check DCDC unit.

Fault Codes and Troubleshooting Chart (continued)

LED

Code

14 F24104 2 DC input voltage is under the

14 F24105 2 DC input voltage is over the speci-

14 F24106 2 Output voltage is over the speci-

1 F31001* 3 2 F32001* 3 4 F34001* 3 4 F34002* 3 4 F34003* 3 4 F34004 3 Time to close breaker on GpAC

5 F35001 3 Motor isolation contactor is open

5 F35002 3 Motor terminal is open circuit or

5 F35003 3 No speed feedback from motor. Check encoder wiring and

7 F37003 3 Battery voltage has dropped below

10 F30101 3 One or more conﬁgured RPDOs

11 F31101 3 Controller is unable to control a

11 F31102 3 The motor control protection

12 F32101* 3 12 F32102 3 Unable to transmit EMCY message. Internal software fault. 13 F33101 3 Internal software fault. Internal software fault. 13 F33102 3 Out of memory. Internal software fault. 13 F33103 3 Unknown error raised by motor

13 F33104 3 Unable to allocate timer. Internal software fault. 13 F33105 3 Unable to post message to queue Internal software fault. 13 F33106 3 Unable to create task in scheduler Internal software fault. 13 F33107* 3 13 F33108 3 Internal software fault. Internal software fault. 13 F33109 3 Internal software fault. Internal software fault. 13 F33110 3 Internal software fault. Internal software fault.

Smart View

Fault Code

Fault

Category

Possible Cause Fault Clearance

speciﬁed minimum.

ﬁed maximum.

has expired.

circuit.

disconnected from controller

critical level.

not received within 3s at start up or 500ms during normal operation.

current in the ﬁeld winding.

subsystem unexpectedly disabled the PWM.

model code.

Check battery.

Check battery

Check vehicle wiring.

Cycle power and restart breaker close sen

Check isolator contactor and wiring

Check motor wiring. Check controller condition.

speed measurement signal. Check controller voltage

supply.

Check status of all nodes on CANbus

Check ﬁeld is wired to correct terminals.

Check for the presence of other faults that may indicate root cause of the problem.

Internal software fault.

Fault Codes and Troubleshooting Chart (continued)

LED

Code

13 F33111 3 Internal software fault. Internal software fault. 13 F33112 3 Internal software fault. Internal software fault.

13 F33113 3 Internal software fault. Internal software fault. 13 F33114 3 Internal software fault. Internal software fault. 13 F33115 3 Internal software fault. Internal software fault. 13 F33116 3 Internal software fault. Internal software fault. 13 F33117* 3 13 F33118* 3 13 F33119 3 Internal software fault. Internal software fault. 13 F33120 3 Current sensor auto-zero current

13 F33121 3 Communication error between

13 F33122 3 Motor rotation detected as wrong

13 F33123 3 Motor rotation stalled. Check motor wiring 13 F33124 3 Internal software fault. Internal software fault. 14 F34101 3 EMCY message received from

1 F41001 4 EEPROM or ﬂash conﬁguration

1 F41002 4 VPDO mapped to non-existant or

1 F41003 4 At least one conﬁguration object is

1 F41004 4 At least one conﬁguration object

1 F41005 4 Unable to automatically conﬁgure

1 F41006 4 Unable to set battery voltage. Check auxillary drives

2 F42001* 4 4 F44001 4 Line contactor did not close when

4 F44002 4 Line contactor closed when coil is

Smart View

Fault Code

Fault

Category

Possible Cause Fault Clearance

out of range.

host and DSP processors

direction.

non-Sevcon node and anonymous EMCY level is set to 3.

data corrumpted and data cannot be recovered.

invalid object.

out of range.

is out of range where one object’s range depends on another.

I/O and vehicle setup.

coil is energized.

deenergized.

Internal software fault.

Internal software fault

Check motor wiring

Check status of nonSevcon nodes on CANbus.

Check all VPDO mappings.

Set conﬁguration object to valid value. Out of range object can be identiﬁed using 0x6621 or Engineering DVT CLI window.

Check all dynamic range objects. Engineering DEV CLI window indicates the object out of range.

Check autoconﬁguration objects.

support low voltage conﬁguration.

Check line contactor and wiring.

Fault Codes and Troubleshooting Chart (continued)

LED

Code

5 F45001* 4 5 F45002* 4

5 F45003 4 VERLOG signal failure. Check peripheral devices. 6 F46001 4 Digital input wire-o. Check wiring. 6 F46002 4 Analogue input outside of allowed

6 F46003 4 Contactor driver over current. Ensure contactor doesn’t

6 F46004 4 Contactor driver unable to achieve

6 F46005 4 Contactor driver not working. Internal hardware fault. 6 F46006 4 Contactor driver over temperature. Ensure contactor driver

6 F46007 4 Contactor driver unable to achieve

6 F46008 4 Contactor driver MOSFET short

7 F47002 4 Capacitor voltage did not rise

7 F47003 4 The voltage applied to the KL

8 F48001 4 Controller heat sink has reached

11 F41101 4 Encoder wire-o is detected. Check encoder wiring. 11 F41102 4 Motor current exceeded control-

11 F41103 4 Motor controller unableto main-

11 F41104 4 Motor control tripped due to mot-

11 F41105 4 Encoder is not aligned properly. Ensure encoder oset is

11 F41106 4 Large rate of change of current

11 F41107 4 Measured capacitor voltage has

Smart View

Fault Code

Fault

Category

Possible Cause Fault Clearance

range.

current target in current mode.

circuit detected.

above 5V at power up.

15/30 is above the controller rated maximum.

citical high temperature and has shut down.

ler-rated maximum.

tain control of motor currents.

er overspeed.

detected multiple times. Suspected MOSFET, motor or wiring short circuit.

exceeded controller maximum.

Check wiring

exceed maximum current and check contactor wiring.

Ensure contactor driver current target is within range.

doesn’t exceed maximum current and check contactor wiring.

Ensure contactor driver current target is within range.

Internal hardware fault.

Check power wiring.

Check KL 15/30 voltage.

Allow controller to cool down to normal operating temperatures.

Check motor conﬁguration. and wiring.

Check motor conﬁguration. ensure motor speed is not too high.

correctgly set or realign encoder.

Check motor wiring, especially for motor terminals shorted to B-. Check controller condition.

Check motor conﬁguration and wiring.

Fault Codes and Troubleshooting Chart (continued)

LED

Code

11 F41108 4 Unable to control output current. Check wiring. 12 F42101 4 CANbus fault condition detected

12 F42102 4 CANopen slave has not transmit-

12 F42103 4 CANbus fault condition detected

12 F42104 4 CANbus fault condition detected

12 F42105 4 CANbus fault condition detected

12 F42106 4 CANbus fault condition detected

12 F42107 4 CANbus fault condition detected

12 F42108 4 CANbus fault condition detected

12 F42110 4 Received RPDO doesn’t contain

12 F42111 4 Heartbeat not received within con-

12 F42112* 4 Internal CANbus fault. Internal software fault. 12 F42113 4 Internal CANbus fault. Internal software fault. 12 F42114 4 Internal CANbus fault. Internal software fault. 12 F42115 4 Internal CANbus fault. Internal software fault. 12 F42116 4 Internal CANbus fault. Internal software fault. 12 F42117 4 Internal CANbus fault. Internal software fault. 12 F42118 4 Internal CANbus fault. Internal software fault. 12 F42119 4 Internal CANbus fault. Internal software fault. 12 F42120 4 Internal CANbus fault. Internal software fault. 12 F42121 4 Internal CANbus fault. Internal software fault. 12 F42122 4 Internal CANbus fault. Internal software fault. 12 F42123 4 Internal CANbus fault. Internal software fault. 12 F42124 4 Internal CANbus fault. Internal software fault. 12 F42125* 4 12 F42126* 4 13 F43101 4 DSP reports invalid protocol ver-

13 F43102 4 Internal hardware fault. Internal hardware fault. 13 F43103 4 Attempting to set too man faults. Internal software fault. 13 F43104 4 Communication error between

Smart View

Fault Code

Fault

Category

Possible Cause Fault Clearance

on multinode system.

ted boot-up message at power up.

on multinode system.

enough bytes.

ﬁgured time out.

sion on dual processor platform.

host and DSP processors.

Check CANbus wiring.

Check status of all nodes on CANbus.

Check CANbus wiring.

Check PDLOs on all CANbus nodes are conﬁgured correctly and match up.

Check status of all nodes on CANbus.

Internal software fault.

Internal hardware fault.

Fault Codes and Troubleshooting Chart (continued)

LED

Code

13 F43105 4 Less than 10% of the stack is free

13 F43106 4 An internal logic supply rail has

14 F44101 4 EMCY message received from

1 F51001 5 Detected controller hardware ver-

1 F51002 5 Calibration settings in controller

3 F53001 5 Voltage on B+ terminal exceeds

3 F53002 5 Motor current exceeded control-

3 F53003 5 MOSFET/IGBT s/c detection on M1

3 F53004 5 MOSFET/IGBT s/c detection on M1

3 F53005 5 MOSFET/IGBT s/c detection on M2

3 F53006 5 MOSFET/IGBT s/c detection on M2

3 F53007 5 MOSFET/IGBT s/c detection on M3

3 F53008 5 MOSFET/IGBT s/c detection on M3

3 F53009 5 Unable to complete MOSFET/IGBT

3 F53010 5 IGBT driver failure Check status of IGBT 3 F53011 5 IGBT driver failure Check status of IGBT 3 F53012 5 IGBT driver failure Check status of IGBT 3 F53013 5 IGBT driver failure Check status of IGBT 3 F53014 5 IGBT driver failure Check status of IGBT 3 F53015 5 IGBT driver failure Check status of IGBT 13 F53101 5 Unable to identify hardware Internal hardware fault 14 F54101 5 EMCY message received from

Smart View

Fault Code

Fault

Category

Possible Cause Fault Clearance

on one of the RTOS tasks.

gone out of range.

non-Sevcon node and anonymous EMCY level was set to 4.

sion incompatible with software.

are out of range.

rated maximum for controller.

ler-rated maximum.

top devices.

bottom devices.

top devices.

bottom devices.

top devices.

bottom devices..

tests at power up.

non-Sevcon node and anonymous EMCY level is set to 5.

Internal hardware fault.

CVheck status of nonSevcon nodes on CANbus.

Check correct software is programmed into controller. Reprogram if necessary.

Controller requires recalibration in production.

Check battery condition and wiring.

Check motor conﬁguration and wiring.

Check motor wiring. Check controller condition.

Internal software fault.

Check status of nonSevcon nodes on CANbus.

Appendix A: Industry Standards

The following text is provided as recommended by Part II, “For the User”, of ANSI/ITSDF B56.8-2011, Safety Standard for Personnel and Burden Carriers. The manufacturer strongly endorses the contents of this speciﬁcation.

6 GENERAL SAFETY PRACTICES

6.1 Introduction

6.1.1 Like other machines, carriers can cause injury if improperly used or maintained. Part II contains broad safety practices applicable to carrier operation. 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 aect 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 aect 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 aect 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.

6.3 Nameplates, Markings, Capacity, and Modiﬁcations

6.3.1 The user shall maintain in a legible condition all nameplates, warnings, and instructions, which are supplied by the manufacturer.

6.3.2 Except as provided in 6.3.4, no modiﬁcations or alterations to a carrier, which may aect 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 axed 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) Ax a permanent and readily visible label on the carrier stating the manner in which the carrier has been modiﬁed or altered together with the date of the modiﬁcation or alteration, and the name of the organization that accomplished the tasks.

6.4 Changing and Charging Storage Batteries for Electric Personnel and Burden Carriers

6.4.1 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.

6.4.2 The user shall periodically inspect facilities and review procedures to be certain that ANSI/NFPA 505 or as required by local ordinance, are strictly complied with, and shall familiarize carrier operators with it.

6.4.3 Maintenance and storage areas for carriers shall be properly ventilated to avoid ﬁre hazards in accordance with applicable ﬁre codes and ordinances.

Ventilation for internal combustion engine powered carriers shall be provided to remove ﬂammable vapors (gases), fumes and other ﬂammable materials. Consult applicable ﬁre codes for speciﬁc levels of ventilation.

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.

6.7 Control of Noxious Gases and Fumes

When equipment powered by internal combustion engines is used in enclosed areas, the atmosphere shall be maintained within limits speciﬁed in the American Conference of Governmental Industrial Hygienists publication, “Threshold Limit Values for Chemical Substances and Physical Agents in the Workroom Environment.” This may be accomplished by ventilation provided by the user, or the installation, use, and proper maintenance of emission control equipment recommended or provided by the manufacturer of the equipment.

6.8 Warning Device(s)

6.8.1 The user shall make periodic inspections of the carrier to be certain that the sound-producing and/or visual device(s) if so equipped are maintained in good operating condition.

6.8.2 The user shall determine if operating conditions require the carrier to be equipped with additional sound producing or visual devices or both and be responsible for providing and maintaining such devices, in accordance with the manufacturer’s recommendations.

6.9 Safety Interlocks

The user shall make periodic inspections of the carrier to be certain that the safety interlock system, if so equipped, is operating properly.

7 OPERATING SAFETY RULES AND PRACTICES

7.1 Personnel and Burden Carrier Operator Qualiﬁcations

Consult applicable ﬁre and safety codes for the speciﬁc ventilation levels required as well as the use of explosion proof electrical apparatus. SAE J1718 can be followed to check for hydrogen gas levels.

6.5 Hazardous Locations

6.5.1 The user shall determine the hazard classiﬁcation of the particular atmosphere or location in which the carrier is to be used in the accordance with ANSI/NFPA 505.

6.5.2 The user shall permit in hazardous areas only those carriers approved and of the type required by ANSI/NFPA 505.

6.6 Lighting for Operating Area

The user, in accordance with his responsibility to survey the environment and operating conditions, shall determine if the carrier requires lights and, if so, shall equip the carrier with appropriate lights.

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, and all other applicable parts of this Standard and the operators’ manual.

7.2 Personnel and Burden Carrier Operators’ Training

7.2.1 The user shall conduct an operators’ training

program.

7.2.2 Successful completion of the operators’ training program by the operator shall be required before operation of the carrier. The program shall be presented in its entirely to all new operators and not condensed for those claiming previous experience.

7.2.3 The user shall include as a minimum in the operators’ training program the following:

(a) Instructional material provided by the manu-

facturer 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 aect 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 o power, turn o 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.

7.3.1.10 Do not add to, or modify, the carrier.

7.3.1.11 Carriers shall not be parked or left unattended such that they block or obstruct ﬁre aisles, access to stairways, or ﬁre equipment.

7.3.1.12 Only operate carrier while within operator’s station.

7.3.2 Traveling

7.3.2.1 Observe all trac regulations, including authorized speed limits. Under normal trac conditions keep to the right. Maintain a safe distance, based on speed of travel, from a carrier or vehicle ahead; and keep the carrier under control at all times.

7.3.2.2 Yield the right of way to pedestrians, ambulances, ﬁre trucks, or other carriers/vehicles in emergency situations.

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 trac 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 o 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.

7.3.2.14 Reduce carrier speed to negotiate turns.

7.3.2.15 Avoid any action verbal or physical by an operator or passenger, which could cause the operator to be distracted.

7.3.3 Loading

tanks. 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 o the premises.

7.3.3.1 Refer to operators’ manual for loading in-

struction.

7.3.3.2 Handle only stable and safely arranged loads. When handling o-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 Care of Personnel and Burden Carriers

7.3.4.1 Read and follow operators’ manual.

7.3.4.2 At the beginning of each shift during which the carrier will be used, the operator shall check the carrier condition and inspect the tires, warning devices, lights, battery(s), speed and directional controllers, brakes, safety interlocks, and steering mechanism. If the carrier is found to be in need of repair or is in any way unsafe, the matter shall be reported immediately to the user and the carrier shall not be operated until restored to safe operating condition.

7.3.4.3 If during operation the carrier becomes unsafe in any way, the matter shall be reported immediately to the user, and the carrier shall not be operated until it has been restored to safe operating condition.

7.3.4.4 Do not make repairs or adjustments unless speciﬁcally trained and authorized to do so.

7.3.4.5 Before refueling, the engine shall be stopped and allowed to cool. The operator and passengers shall leave the carrier before refueling.

7.3.4.6 Spillage of hazardous materials shall be contained immediately and addressed via appropriate hazardous materials regulations.

7.3.4.7 Do not operate a carrier with a leak in the fuel system or battery(s). Battery(s) shall be charged and serviced per manufacturer’s instructions.

7.3.4.8 Do not use open ﬂames for checking electrolyte level in storage battery(s) or liquid level in fuel

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.

(d) Chock wheels and support carrier before working underneath it.

(e) Before disconnecting any part of the engine fuel system, be sure the shuto 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 trac.

(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) 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 of the carrier until the cause of the leak has been repaired.

(n) The carrier manufacturer’s capacity, operation, and maintenance instruction plated, tags, or decals shall be maintained in legible condition.

(o) Batteries, motors, speed and directional controllers, limit-switches, protective-devices, electrical conductors/insulators, and connections shall be inspected and maintained per carrier manufacturer’s recommendation.

(p) Carriers shall be kept clean to minimize hazards and facilitate detection of components needing service.

(q) Modiﬁcations and additions which aect 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.

Appendix B: Programming the Safe-T-Lock Switch

SAFE-T-LOCK™ is an optional programmable code switch which prevents unauthorized use of the vehicle (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 factory installed or

purchased separately to upgrade existing vehicles.

The switch allows plant and facility managers to input up to 99 dierent 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 250-hour mark is reached.

Each user can select a four-to eight digit personal access code and a separate supervisor user menu programs the unit. The switch will provide the last user ID code when prompted by the supervisor. Only users with active ID codes can operate the vehicle, virtually eliminating all unauthorized use.

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 required. To do this you must go into the Add / Delete User Menu.

2 – Go into Add / Delete User Menu. Press 2 ENTER. There will be a beep along with two Red LED ﬂashes

indicating you are in Menu 2. Press 0 1 ENTER. If there is a Red ﬂash and a low beep, it indicates that user location 01 has already been assigned. To remove location 01, press ENTER again. This will delete the location from use.

Add location 01. Press 0 1 ENTER. You should now get a Green ﬂash along with an up tone beep indicating the location is ready to be added or assigned to a user. Press ENTER. You will get a Green LED ﬂash along with a beep. The user location has been added.

At this point you can, in the same way, check on and add more user locations.

Before leaving Menu 2, check to make sure that location 01 and any others have been added. Press 0 1 ENTER. There should be a 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.)

4 – Log onto the User Mode. Press 0 1 1 2 3 4 ENTER. The switch will close and the Green LED will ﬂash at a slow rate.

5 – Change User PIN. First decide on a new PIN. In this example, 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, and 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 as you did in

the User Mode, put the new PIN in twice and enter each time. Example: Press 5 4 3 2 1 ENTER, and again 5 4 3 2 1 ENTER. The switch will give an indication that the PIN was changed.

8 – Go out of Menu 1. Press CE. Press CE again to

Log O 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 O the Supervisor Mode.

Note: If the switch is left unattended in Supervisor Mode, it will automatically exit the mode after approximately one minute.

13 – If you are unable to get into the Supervisor Mode after trying either the default PIN or a newly assigned PIN, go back to Step 1 and reset the switch.

If you need assistance or have questions about programming or installing the SAFE-T-LOCK, call Tech Support at 1-800-241-2869.

Appendix C: Speciﬁcations

Model Deck Width Deck Length Deck Capacity Towing Capacity Turning

Radius

PC-325 NXG 31.5” 19.5” 750 lbs 2,000 lbs 63.5”

PCT-3250 NXG 31.5” 19.5” 750 lbs 5,000 lbs 63.5”

PC-300 NXG 31.5” 19.5” 750 lbs N/A 63.5”

PC-320 NXG 31.5” 19.5” 750 lbs 2000 lbs 63.5”

PCT-3200 NXG 31.5 19.5 750 lbs 5000 lbs 63.5

PC-640 NXG Front: 35.5

Rear:35.5

Front: 18”

Rear: 14”

1,000 lbs 5,000 lbs 63.5

Appendix D: Components—Electrical

Part Part Number

Key Switch, 3-position (standard) EV-E160

Key Replacement, set of 2 EV-E100

Directional Switch, 3 position Rocker EV-E156

Horn EV-E130

Horn Button EV-E041

10 Amp Fuse EV-E015

Fuse Holder EV-E016

Charger Receptacle EV-E027

Charger Cord EV-E026

Onboard Battery Charger, 24 volt EV-E801-24

Onboard Battery Charger, 36 volt EV-E801-36

Onboard Battery Charger, 48 volt EV-E801-48

Directional Switch, 3 position Toggle EV-E035

Perma-Key Switch EV-E194PK

On/O Switch EV-E017

Programmable Code Security Switch EV-E901

Headlight/Taillight Switch, Rocker EV-E155

Single LED Charge Status Plate EV-E808L

Foot Presence Switch EV-E128

Appendix D: Components—Electrical (cont.)

Part Part Number

Battery Watering System – 24V GC135 EV-E900-6

Battery Watering System – 24V GC145 EV-E900-7

Battery Watering System – 36V GC135 EV-E900-2

Battery Watering System – 36V GC145 EV-E900-1

Battery Watering System – 48V FS8D EV-E900FX-310

Headlight/Taillight – 24 / 36 volt EV-E210-S

Headlight/Taillight – 48 volt EV-E210-48-S

Headlight/Taillight/Brake light – 24 / 36 volt EV-E191

Headlight/Taillight/Brake light – 48 volt EV-E191-48

Flashing Safety Beacon – Amber EV-E183

Flashing Safety Beacon – Blue EV-E182B

Flashing Safety Beacon – Red EV-E182R

Back-up Alarm EV-E159A

Proximity Alarm EV-E149

Hitch, Spring-Loaded Clevis, 1” pin EV-F130H

Hitch, Spring-Loaded Clevis, 5/8” pin EV-F178H

Hitch, Pin EV-F134P

Hitch, Pintle EV-F092

Hitch, Eye 2-3/8” EV-F132

Hitch, Auto Coupling EV-F133H

Hitch, 3-Tier Assembly with Pin EV-F134

Appendix E: Rear End

Drawing

Number

1 Lever, Park Brake, Handle w/Switch 28016 1 2 Cable, Brake 40”” 28067 1 3 Brake, Hydraulic, Master Cylinder 3/4” Bore 28017 1 4 Brake, Hydraulic, Hose Line Assembly 28018 1 5 Brake Drum 30036 2 6 Brake, Hydraulic, LH Assembly 30025 1 7 Brake, Hydraulic, RH Assembly 30027 1 8 Cap, Brake Master Cylinder Replacement 12054 2

Description Part # Qty.

Appendix F: Front Axle

# Description Part # Qnty

1 Hub, Wheel 5 Lug w/Race 26058 2 1 Hub, Wheel 5 Lug w/Race 26054 2 2 Strut, Front Steering Weldment-Pot 36035 1 3 Tire and Wheel, 5 Lug, 4.00x8, Non-Marking 26066 2 3 Tire and Wheel, 5 Lug, 4.00x8,, Pneumatic 26060 2 3 Tire and Wheel, 5 Lug, 4.00x8,, Soft Solid 26061 2 3 Tire and Wheel, 4 Lug, 4.00x8,, Pneumatic 26055 2 3 Tire and Wheel, 4 Lug, 4.00x8,, Soft Solid 26056 2 3 Tire and Wheel, 4 Lug, 4.00x8,, Non-Marking 26066 2 4 Bearing, Hubcap, 18054 2 5 Bearing, Tapered Roller, 1” 18060 5 6 Oil Seal 18058 3 7 Nut, Lug, 1/2-20 14236 10 8 Washer, 3/8 USS Flat, ZN 14155 1 9 Washer, 3/8 ID, Split, ZN 14156 1 10 Nut, Hex 3/8-16 Zinc 14153 1 11 Horn with Bracket 16100 1 12 Washer, Hub Bearing 18079 2 13 Nut, 1/4”, Castle 14235 2 14 Bolt, 1/4-20x1.0” HHCS, GR. 5, ZN 14161 1

Appendix G: Floor Panel

# Description Part # Qnty

1 Plate, Floor, PCT-3500 Series 22184 1 2 Throttle, Pedal Assembly, Flush Mount 28013 1 3 Switch, Foot, SPDT, Momentary, 20A 38100 1 4 Pad, Brake Pedal 12014 1 5 Brake Pad Pedal PCT-3500 Series 36136 1 6 Brake Pedal Weldment PCT-3500 Series 36046 2 7 Screw, 1/4-20x1/2” PH Type F, Zn Pl 14208 8 8 Screw, 10/32 x1/2” PH Type F ZnPl 14207 3 9 Screw, 1/4-20x1/2”PHMS,Zn 14190 3 10 Screw, 10/32x1 1/2”, PHIL Panhead MA 14167 2 11 Nut, 10/32, Hex, Zn 14160 2 12 Nut, 1/4-20, Hex, Zn 14162 2 13 Lockwasher, 1/4” Zn 14164 2 14 Bolt, 1/4-20x1” HHCS, GR. 5, Zn 14161 2 15 Plate, Cover, Master Cylinder PCT-3500 Series 22151Y 1 13 Nut, 1/4”, Castle 14235 2 14 Bolt, 1/4-20x1.0” HHCS, GR. 5, ZN 14161 1

Appendix H: Transaxle—PC Series

# Description Part Number Quantity

3 Gear, Input See Kit 1

4 Ring, Retaining EV-T016 3

5 O-Ring EV-T014 3

6 Bearing, Ball EV-T015 1

7 Bearing, Ball EV-T013 1

8 Plug, End Cap EV-T017 2

9 Bearing, Ball EV-T011 2

10 Gear, Intermediate Assembly See Kit

11 O-Ring EV-T010 2

12 Gear, Final Drive See Kit

13 Bearing, Ball EV-T008 2

15 Screw, Cap EV-T006 4

16 Nut, Lock EV-T007 4

17 Plate, Cover EV-T018 1

18 Plug, Fill EV-T020 1

19 Screw, Cover Plate EV-T021 10

23 Brake Assembly, Left-Hand Shoe Type EV-T054 1

23 Brake Assembly, Left-Hand Shoe Type (Stock Chaser) EV-T054-S 1

24 Brake Assembly, Right-Hand Shoe Type EV-T055 1

24 Brake Assembly, Right-Hand Shoe Type (Stock Chaser) EV-T055-S 1

25 Shaft, Axle 29” Left Hand (15 1/4” length) EV-T023-29 1

25 Shaft, Axle 32” Left Hand (18 1/8” length) EV-T023-32

25 Shaft, Axle 36” Left Hand (23 1/4 length) EV-T023-36

26 Shaft, Axle Right-Hand EV-T025 1

28 Seal, Oil EV-T030 2

29 Ring, Retaining EV-T029 4

30 Bearing, Ball EV-T028 2

31, 32. 33 Hub and Drum—4-lug assembly with studs EV-T058 2

34 Nut,Flange Hex EV-T064 2

Kit Kit, Gear Set (Includes #3, #10, #12) EV-T065 1

Appendix I: Transaxle—PCT Series Series

# Description Part Number Quantity

3 Gear, Input See Kit 1

4 Ring, Retaining EV-T016 3

5 O-Ring EV-T014 3

6 Bearing, Ball EV-T015 1

7 Bearing, Ball EV-T013 1

8 Plug, End Cap EV-T017 2

9 Bearing, Ball EV-T011 2

10 Gear, Intermediate Assembly See Kit

11 O-Ring EV-T010 2

12 Gear, Final Drive See Kit

13 Bearing, Ball EV-T008 2

15 Screw, Cap EV-T006 4

16 Nut, Lock EV-T007 4

17 Plate, Cover EV-T018 1

18 Plug, Fill EV-T020 1

19 Screw, Cover Plate EV-T021 10

23 Brake Assembly, Left-Hand Shoe Type EV-T054 1

23 Brake Assembly, Left-Hand Shoe Type (Stock Chaser) EV-T054-S 1

24 Brake Assembly, Right-Hand Shoe Type EV-T055 1

24 Brake Assembly, Right-Hand Shoe Type (Stock Chaser) EV-T055-S 1

25 Seal, Oil EV-T076 2

26 Ring, Retaining EV-T077 2

27 Ring, Retaining, Wheel Bearing) EV-T078 4

28 Ring, Retaining EV-T079 2

29 Bearing, Ball EV-T080 2

30 Drum, Brake EV-T075 2

31 Shaft, Left-Hand Axle 32” EV-T081-32 1

31 Shaft, Left-Hand Axle 36” EV-T081-36 1

32 Shaft, Right-Hand Axle EV-T082 1

Kit Kit, Gear Set (Includes #3, #10, #12) EV-T083 1

37 Drum Assembly (5-lug) EV-T075

Appendix I: Beacon (Optional)

Number Description Part Number Quantity

1 Washer, Split Lock, 1/2” ID EV-D011 1

2 Washer, 1/2”ID SAE Zn EV-D018 2

3 Beacon, Pedestal Base EV-E183PD 1

4 Pole, Beacon Mount EV-F8186 1

5 Plate, Beacon Base Mount EV-F8188 1

6 10-32 x 1/2” PHMS EV-G001 2

7 Nut, Hex, 1/2-13 Zn Plated EV-G012 2

8 Locknut, Nylon Insert, 10-32 EV-G013 2

9 1/2-13 x 3.0” RHSN Gr.2 EV-G027 2

10 Plug, Tube End, 1 x 2 EV-G043 1

11 Washer, Rivet, 3/16 ID EV-G066 2

Pack Mule PC NXG, PCT NXG Series Manual

Specifications and Main Features

Frequently Asked Questions

User Manual