INDUSTRIAL ELECTRIC VEHICLE
OWNER’S MANUAL
AND SERVICE GUIDE
PCT-SERIES
Nov 2013
Owner’s Manual and Service Guide – PC & PCT Series
FOREWARD
UPON RECEIPT OF VEHICLE/EQUIPMENT:
Please visually inspect the vehicle for any damage that may have occurred during shipping and have it noted on the carrier’s bill immediately. Be sure to specify the nature of the damage.
This manual is a VERY IMPORTANT tool. Please keep it with the vehicle/equipment at all times. The purpose of this manual is to provide owner, users, lessors and/or lessees with the operating instructions and precautions for the safe and proper operation of the vehicle or equipment. It is the owner, user, lessor or lessees responsibility to ensure that the vehicle/equipment is being used in accordance with its designed intended use.
Please read this ENTIRE manual to familiarize yourself with the safe operation of this vehicle/equipment. Pay particular attention to anything labeled CAUTION, NOTE, OR WARNING!
Due to continuous product improvements, changes or updates may be made to this Manual, making it subject to change without notice. For the most up to date version of the manual, please go to our website:
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/vehicles already purchased or leased.
The Pack Mule Division and/or Wesley International accepts no liability in connection with any errors or omissions in this Manual, and SPECIFICALLY DISCLAIMS any liability for any incidental and consequential damages arising from the use of the information in this Manual.
The use of non OEM (Original Equipment Manufacturer) parts may void the warranty.
Overfilling the batteries may void your warranty.
The PCT tow vehicle is a Class VI Industrial Truck. Only operators trained per OSHA requirements shall operate this vehicle.
NOTES, CAUTIONS AND WARNINGS
Throughout this guide NOTE, CAUTION, and WARNING will be used. Please observe these notes, cautions and warnings.
NOTE
CAUTION
WARNING
A NOTE indicates a condition that should be observed.
A CAUTION indicates a condition that may result in damage to the vehicle.
A WARNING indicates a hazardous condition that could result in severe injury or death.
Owner’s Manual and Service Guide – PC & PCT Series |
2 |
TABLE OF CONTENTS
INTRODUCTION ................................................................................................................................................................................ |
5 |
SAFETY INFORMATION.................................................................................................................................................................... |
6 |
Training........................................................................................................................................................................................... |
6 |
Operator Qualifications ................................................................................................................................................................... |
6 |
Safety Guidelines............................................................................................................................................................................ |
6 |
Loading and Unloading................................................................................................................................................................... |
7 |
Towing ............................................................................................................................................................................................ |
7 |
Maintenance ................................................................................................................................................................................... |
7 |
Ventilation ....................................................................................................................................................................................... |
7 |
INDUSTRY STANDARDS ................................................................................................................................................................. |
8 |
OPERATING INSTRUCTIONS .............................................................................................................................................................. |
12 |
Initial Checklist.............................................................................................................................................................................. |
12 |
Identification.................................................................................................................................................................................. |
12 |
Charging ....................................................................................................................................................................................... |
12 |
Vehicle Controls, Meters, Switches .............................................................................................................................................. |
12 |
Driving .......................................................................................................................................................................................... |
17 |
Towing………………………………………………………………………………………………………………………………………....17 |
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Coasting ....................................................................................................................................................................................... |
17 |
Loading/Unloading........................................................................................................................................................................ |
17 |
Parking ......................................................................................................................................................................................... |
17 |
Startup Checklist for Industrial Trucks………………………………………………………………………………………………………18
MAINTENANCE INSTRUCTIONS ......................................................................................................................................................... |
19 |
Maintenance Schedule ................................................................................................................................................................. |
19 |
Routine Maintenance.................................................................................................................................................................... |
20 |
Batteries ....................................................................................................................................................................................... |
20 |
Battery Safety………………………………………………………………………………………………………………………………….20 |
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Battery Care.................................................................................................................................................................................. |
20 |
Electrolyte Levels.......................................................................................................................................................................... |
21 |
Battery Watering System .............................................................................................................................................................. |
21 |
Cleaning Batteries ........................................................................................................................................................................ |
21 |
Battery Replacement .................................................................................................................................................................... |
21 |
Lifting the Vehicle ......................................................................................................................................................................... |
22 |
Lubrication .................................................................................................................................................................................... |
22 |
Brakes…………………………………………………………………………………………………………………………………………..23 |
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Tires and Wheels.......................................................................................................................................................................... |
24 |
COMPONENTS - ELECTRICAL............................................................................................................................................................. |
25 |
Basic Electrical Components ........................................................................................................................................................ |
25 |
Onboard Battery Charger ............................................................................................................................................................. |
26 |
Motor ............................................................................................................................................................................................ |
28 |
3 |
Owner’s Manual and Service Guide – PC & PCT Series |
Controller ...................................................................................................................................................................................... |
28 |
Battery Discharge Indicator (BDI) ................................................................................................................................................. |
33 |
Speed Control Pedal..................................................................................................................................................................... |
33 |
Solenoid........................................................................................................................................................................................ |
33 |
Parts List – Electrical .................................................................................................................................................................... |
35 |
Parts List – Available Options ...................................................................................................................................................... |
35 |
COMPONENTS - MECHANICAL .......................................................................................................................................................... |
36 |
Parts List – Front Wheel Steer Assembly ..................................................................................................................................... |
36 |
Transaxle - Exploded View……………………………………………………………………………………………………………….….37 |
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Transaxle Parts List……………………………………………………………………………………………………………………….…..38 |
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Transaxle Troubleshooting Guide……………………………………………………………………………………………………….….39 |
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Hitch Options…………………………………………………………..………………………………………………………………………41 |
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Owner’s Manual and Service Guide – PC & PCT Series |
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INTRODUCTION
Thank you for choosing a Pack Mule Industrial Electric Vehicle, proudly built by Wesley International in the USA. At Wesley International, we are committed to providing you the best quality product backed by exceptional customer service. This owner’s manual and service guide is provided to help you get the most out of your new vehicle, for many years to come.
RECORD YOUR PRODUCT INFORMATION
Model #: |
|
Serial #: |
Purchase Date:
REGISTER YOUR PRODUCT
PRODUCT REGISTRATION IS REQUIRED FOR WARRANTY COVERAGE.
Registration is easy. Simply go to http://www.packmule.com/support/warranty/ and complete the online form and click submit. That’s it! Then you will be entitled to free parts for any defective items, as outlined in our warranty document.
IF YOU NEED HELP
You will find many answers to common problems within this manual or online at www.packmule.com. If you do not find
Just email us at info@wesleyintl.com or call
Wesley International
3680 Chestnut Street
Scottdale, GA 30079
Phone (404) 292-7441 • Toll Free (800) 241-2869 • Fax (404) 292-8469
info@wesleyintl.com
www.wesleyinternational.com
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Owner’s Manual and Service Guide – PC & PCT Series |
SAFETY INFORMATION
The responsibility of safety lies with four main groups: manufacturers, owners/lessees, operators and maintenance personnel. This manual has been designed to assist the owner-operator in operating and maintaining the vehicle in a safe manner, in accordance with the procedures and standards to which the vehicle was designed and intended for use.
TRAINING
Vehicle owners/lessees are responsible for instructing their personnel in its safe operation. Owner/lessees must explain the vehicle’s characteristics, features, operation of its controls, and safe driving practices. We strongly recommend that owners/lessees first become familiar with the conditions of the place where the vehicle will be operated in order to assess its effect on safe operation. Training should occur under the conditions of the operating environment while adhering to the safety guidelines and include:
Safety guidelines
Operation of the vehicle under the conditions in which it will be operated
Operation of all controls
Safe driving practices
A driving and operating test
OPERATOR QUALIFICATIONS
Operators should be selected based on their ability to safely operate the vehicle, including vision, hearing, physical and mental capabilities. Operators must:
Demonstrate a working knowledge of all controls
Understand all safety guidelines
Be evaluated by a designated trainer who certifies the operator’s ability to properly drive and park the vehicle under the conditions in which the vehicle will be used
Know how to properly load and unload cargo and passengers
Recognize maintenance problems
SAFETY GUIDELINES
All Pack Mule vehicles are designed for use on smooth surfaces in and around industrial plants and warehouses. Not intended for agricultural use. While made of components that are unaffected by the rain, they are not intended for continuous outdoor use, traversing up and down steep grades, or travelling on public roads/highways as the tires are not configured for these purposes.
Follow these guidelines to safely drive the vehicle:
Read, understand and observe all labels affixed to the vehicle
Do not start the vehicle without checking the brakes first
Do not mount or dismount the vehicle when the key is in the ON position
Do not drive the vehicle if the accelerator requires excessive pressure
Do not park or operate the vehicle near flammable objects or in a flammable or hazardous environment
Use only necessary power
Keep both hands on the steering wheel while operating the vehicle
Accelerate and decelerate slowly and in a controlled manner
Always reduce speed to compensate for poor terrain or conditions
Always maintain adequate distance between vehicles, people, and obstacles
Do not use the vehicle to push objects
Do not allow the tires to lose contact with the ground
Proceed around low overhangs with caution. Be sure there is enough clearance for the operator’s head and the highest point of the vehicle or any attached accessories.
Never abruptly change direction
Always drive directly up an incline; never across
Never exceed the designated passenger, load or towing capacity
On grades, it is possible for vehicles to coast at greater than normal speeds encountered on a flat surface. To prevent loss of vehicle control and possible serious injury, speeds should be limited to no more than maximum speed on level ground.
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Owner’s Manual and Service Guide – PC & PCT Series |
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SAFETY INFORMATION
Good common sense and prudent driving practices do more to prevent accidents and injuries than all of the warnings and instructions combined. Wesley International strongly suggests that the owner-operator read this entire manual paying particular attention to the CAUTIONS and WARNINGS contained therein
Loading and Unloading
Follow these guidelines when loading and unloading cargo from the vehicle or trailers:
Turn the vehicle off while loading
Do not exceed the maximum passenger or cargo load capacity
Carefully and evenly position all loads
Secure cargo so that nothing can easily fall off of the vehicle or trailer
Be extremely careful carrying loads that extend beyond the vehicle’s deck
TOWING
Follow these guidelines when towing:
Turn the vehicle off when connecting equipment that will be towed
Always use a properly installed hitch that matches the trailer tongue (Optional hitches available from Wesley International)
Do not exceed the maximum towing capacity
Do not exceed 5 mph when towing
Take extreme care when towing down an incline. Do not tow trailers down an incline with a grade of more than 15%.
MAINTENANCE
Always maintain your vehicle in accordance with the service schedule within this manual and keep complete records of the maintenance history of the vehicle. Ensure the maintenance personnel performing any service or repair work on the vehicle are trained and qualified to do so. Be sure to disable the vehicle before performing any maintenance including removing the key from the key switch and removal of a battery cable.
WARNING |
Always insulate any tools used within the battery area in order to prevent sparks or battery |
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explosion caused by shorting the battery terminals or associated wiring. |
Be sure to check the polarity of each battery terminal and be sure to rewire the batteries correctly. Never install a wire instead of a proper fuse, even for a temporary fix. It may cause extensive damage and possible fire. Do not use a screwdriver or other metal object to remove fuses. Doing so may cause an electrical short and damage the system. Do not modify or tamper with any part of the operating or speed control systems. All inspections and adjustments must be made by a qualified technician.
Always support the vehicle using wheel chocks and safety stands. Never get under a vehicle that is supported by a jack. Lift the vehicle in accordance with the instructions in this manual.
Always test drive the vehicle after any repairs or maintenance in a safe area free of any other vehicles or pedestrians.
VENTILATION
WARNING
Hydrogen gas is generated in the charging cycle of batteries and is explosive in concentrations as low as 4%. Because hydrogen gas is lighter than air, it will collect in the ceilings of buildings and therefore, proper ventilation is required. Five air exchanges per hour is considered the minimum ventilation required.
Always use a dedicated circuit for each battery charger. Do not permit other appliances to be plugged into the receptacle when the charger is in operation.
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Owner’s Manual and Service Guide – PC & PCT Series |
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
6.1Introduction
6.1.1Like 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.
6.1.2Premise review — The user shall periodically review their premises, and as conditions warrant, identify areas where carriers should not be operated and to identify possible hazards such as the following examples:
(a)Steep Grade — In areas where steep grades exist, carrier operation should be restricted to the designated vehicle’s pathways where possible, and shall be identified with a suitable warning giving the following information:
“Warning, steep grade.”
(b)Wet Areas — Wet areas could cause a carrier to lose traction and could affect steering, stability and braking.
(c)Sharp Turns, Blind Spots, Bridge Approaches — Sharp turns, blind spots, bridge approaches, and other potentially hazardous areas shall be identified with a suitable warning to the operator of the nature of the hazard and stating the proper precautions to be taken to avoid the hazard.
(d)Loose Terrain — Loose terrain could cause a carrier to lose traction and could affect steering, stability, and braking.
6.2Operation
Experience has shown that carriers, which comply with the provisions, stated in paragraphs 9.4, 9.5, and 9.6 are stable when properly operated and when operated in accordance with specific safety rules and practices established to meet actual operating terrain and conditions. However, improper operation, faulty maintenance, or poor housekeeping may contribute to a condition of instability and defeat the purpose of the standard. Some of the conditions which may affect stability are failure of the user to follow safety practices; also, ground and floor conditions, grade, speed, loading, the operation of the carrier with improper loads, battery weight, dynamic and static forces, and the judgment exercised by the carrier operator.
(a)The user shall train carrier operators to adhere strictly to the operating instructions stated in this Standard.
(b)The user shall survey specific operating conditions and environment, and establish and train carrier operators to comply with additional, specific safety practices.
Owner’s Manual and Service Guide – PC & PCT Series
6.3Nameplates, Markings, Capacity, and Modifications
6.3.1The user shall maintain in a legible condition all nameplates, warnings, and instructions, which are supplied by the manufacturer.
6.3.2Except as provided in 6.3.4, no modifications or alterations to a carrier, which may affect the capacity, stability, or safe operation of the carrier, shall be made without the prior written approval of the original carrier manufacturer or a successor thereof. When the carrier manufacturer or its successor approves a modification or alteration, appropriate changes shall be made to capacity plates, decals, tags, and operation and maintenance manuals.
6.3.3As required under paragraphs 6.3.1 or 6.3.2, the manufacturer shall be contacted to secure new nameplates, warnings, or instructions, which shall then be affixed in their proper place on the carrier.
6.3.4In the event that the carrier manufacturer is no longer in business and there is no successor in interest to the business, the user may arrange for a modification or alteration to a carrier, provided however, the controlling party shall:
(1)Arrange for the modification or alteration to be designed, tested, and implemented by an engineer(s) expert in carrier(s) and their safety;
(2)Maintain a permanent record of the design, test(s), and implementation of the modification or alteration;
(3)Make appropriate changes to the capacity plate(s), decals, tags, and operation and maintenance manuals;
(4)Affix a permanent and readily visible label on the carrier stating the manner in which the carrier has been modified or altered together with the date of the modification or alteration, and the name of the organization that accomplished the tasks.
6.4Changing and Charging Storage Batteries for Electric Personnel and Burden Carriers
6.4.1The user shall require battery changing and charging facilities and procedures to be in accordance with ANSI/NFPA 505 or as required by local ordinance.
6.4.2The 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.
8
INDUSTRY STANDARDS
6.4.3 Maintenance and storage areas for carriers shall be properly ventilated to avoid fire hazards in accordance with applicable fire codes and ordinances.
Ventilation for internal combustion engine powered carriers shall be provided to remove flammable vapors (gases), fumes and other flammable materials. Consult applicable fire codes for specific levels of ventilation.
Ventilation for electric powered carriers shall be provided to remove the accumulation of flammable hydrogen gas emitted during the battery charging process.
The amount of hydrogen gas emitted depends upon a number of factors such as the condition of the batteries, the output rate of the battery charger and the amount of time the batteries are on charge. Because of the highly volatile nature of hydrogen gas and its propensity to accumulate in pockets, a minimum number of air changes per hour is required during charging.
Consult applicable fire and safety codes for the specific ventilation levels required as well as the use of explosion proof electrical apparatus. SAE J1718 can be followed to check for hydrogen gas levels.
6.5Hazardous Locations
6.5.1The user shall determine the hazard classification of the particular atmosphere or location in which the carrier
is to be use in the accordance with ANSI/NFPA 505.
6.5.2The user shall permit in hazardous areas only those carriers approved and of the type required by ANSI/NFPA
6.6Lighting for Operating Area
The user, in accordance with his responsibility to survey the environment and operating conditions, shall determine if the carrier requires lights and, if so, shall equip the carrier with appropriate lights.
6.7 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.
6.8Warning Device(s)
6.8.1The 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.
9
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
7.1Personnel and Burden Carrier Operator Qualifications
Only persons who are trained in the proper operation of the carrier shall be authorized to operate the carrier. Operators shall be qualified as to visual, auditory, physical, and mental ability to safely operate the equipment according to Section 7, all other applicable parts of this Standard and the operators’ manual.
7.2Personnel and Burden Carrier Operators’ Training
7.2.1The user shall conduct an operators’ training program.
7.2.2Successful 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.
7.2.3The user shall include as a minimum in the operators’ training program the following:
(a)Instructional material provided by the manufacturer including the operators’ manual;
(b)Emphasis on safety of passengers, material loads, carrier operator, and other person(s);
(c)General safety rules contained within this Standard and the additional specific rules determined by the user in accordance with this Standard, and why they were formulated;
(d)Introduction of equipment, control locations and functions, and explanation of how they work when used properly and when used improperly; and surface conditions, grade, and other conditions of the environment which could affect carrier operation;
(e)Operator competency evaluations.
Owner’s Manual and Service Guide – PC & PCT Series
INDUSTRY STANDARDS
7.3Personnel and Burden Carrier Operator Responsibility
7.3.1General Operator Responsibility
7.3.1.1Read and follow operators’ manual.
7.3.1.2Do not operate carrier under the influence of drugs and alcohol.
7.3.1.3Safeguard the pedestrians at all times. Do not drive carrier in a manner that would endanger other persons.
7.3.1.4Riding 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.
7.3.1.5When a carrier is to be left unattended, stop the carrier, apply the parking brake, stop the engine or turn off power, turn off the control or ignition circuit, and remove the key if provided. Additionally, for electric carriers, the forward and reverse directional controls, should be neutralized if a means is provided. Block the wheels if the carrier is on an incline.
7.3.1.6A carrier is considered unattended when the operator is 7.6m (25 ft) or more from the carrier which remains in his view, or whenever the operator leaves the carrier and it is not within his view. When the operator 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.
7.3.1.7Maintain a safe distance from potential hazards, such as edges of ramps and platforms.
7.3.1.8Use only approved carriers in hazardous locations, as defined in the appropriate safety standards.
7.3.1.9Report all accidents to the user.
7.3.1.10Do not add to, or modify, the carrier.
7.3.1.11Carriers shall not be parked or left unattended such that they block or obstruct fire aisles, access to stairways, or fire equipment.
7.3.1.12Only operate carrier while within operator’s
station.
7.3.2 Traveling
7.3.2.1Observe all traffic regulations, including authorized speed limits. Under normal traffic conditions keep to the right. Maintain a safe distance, based on speed of travel, from a carrier or vehicle ahead; and keep the carrier under control at all times.
7.3.2.2Yield the right of way to pedestrians, ambulances, fire trucks, or other carriers/vehicles in emergency situations.
Owner’s Manual and Service Guide – PC & PCT Series
7.3.2.3Do not pass another carrier or vehicle traveling in the same direction at intersections, blind spots, or at other dangerous locations.
7.3.2.4Keep a clear view of the path of travel, observe other traffic and personnel, and maintain a safe clearance.
7.3.2.5Slow down or stop, as conditions dictate, and activate the sound-producing warning device at cross aisles and when visibility is obstructed at other locations.
7.3.2.6Ascend or descend grades slowly.
7.3.2.7Avoid turning, if possible, and use extreme caution on grades, ramps, or inclines; normally travel straight up and down.
7.3.2.8Under all travel conditions the carrier shall be operated at a speed that will permit it to be brought to a stop in a safe manner.
7.3.2.9Make 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.
7.3.2.10Do not operate carrier in a dangerous manner.
7.3.2.11Slow down when approaching, or on, wet or slippery surfaces.
7.3.2.12Do not drive carrier onto any elevator unless specifically authorized to do so. Approach elevators slowly, and then enter squarely after the elevator car is properly leveled. Once on the elevator, neutralize the controls, shut off power, and set parking brakes. It is advisable that all other personnel leave the elevator before a carrier is allowed to enter or exit.
7.3.2.13Avoid running over loose objects, potholes, and
bumps.
7.3.2.14Reduce carrier speed to negotiate turns.
7.3.2.15Avoid any action verbal or physical by an operator or passenger, which could cause the operator to be distracted.
7.3.3 Loading
7.3.3.1Refer to operators’ manual for loading instruction.
7.3.3.2Handle only stable and safely arranged loads. When handling off-center loads, which cannot be centered, operate with extra caution.
7.3.3.3Handle only loads within the capacity of each cargo area of the carrier as specified by the manufacturer.
7.3.3.4Avoid material loads exceeding the physical dimensions of the carrier or as specified by the carrier manufacturer.
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INDUSTRY STANDARDS
7.3.4 Operator Care of Personnel and Burden
Carriers
7.3.4.1Read and follow operators’ manual.
7.3.4.2At 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.
7.3.4.3If 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.
7.3.4.4Do not make repairs or adjustments unless specifically trained and authorized to do so.
7.3.4.5Before refueling, the engine shall be stopped and allowed to cool. The operator and passengers shall leave the carrier before refueling.
7.3.4.6Spillage of hazardous materials shall be contained immediately and addressed via appropriate hazardous materials regulations.
7.3.4.7Do 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.
7.3.4.8Do not use open flames for checking electrolyte level in storage battery(s) or liquid level in fuel 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 off the premises.
8.2 Maintenance Procedures
Maintenance and inspection of all carriers shall be performed in conformance with the following practices and should follow the manufacturer’s recommendations.
(a)A scheduled preventive maintenance, lubrication, and inspection system shall be followed.
(b)Only trained and authorized personnel shall be permitted to maintain, repair, adjust, and inspect carriers.
(c)Before undertaking maintenance or repair, follow the manufacturer’s recommendations for immobilizing the carrier.
(d)Chock wheels and support carrier, before working underneath it.
(e)Before disconnecting any part of the engine fuel system, be sure the shutoff valve, if so equipped, is closed and follow carrier manufacturer’s recommended practice.
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(f)Operation to check performance of the carrier shall be conducted in an authorized area where suitable conditions exist, free of vehicular and pedestrian traffic.
(g)Before returning carrier to service, follow the manufacturer’s instructions and recommended procedures.
(h)Avoid fire hazards and have fire protection equipment present in the work area. Do not use an open flame to check level or leakage of fuel, battery electrolyte, or coolant.
(i)Properly ventilate the work area in accordance with applicable regulations or local ordinance.
(j)Handle fuel cylinders with care. Physical damage, such as dents, scrapes, or gouges, may dangerously weaken the tank and make it unsafe for use.
(k)Brakes, steering mechanisms, speed and directional control mechanisms, warning devices, lights, governors, guards, and safety devices shall be inspected regularly and maintained in accordance with manufacturer’s recommendations.
(l)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 affect capacity and safe carrier operation shall not be performed without manufacturer’s prior written authorization; where authorized modifications have been made, the user shall ensure that capacity, operation, warning, and maintenance instruction plates, tags, or safety labels are changed accordingly.
(r)Care shall be taken to ensure that all replacement parts are interchangeable with the original parts and of a quality at least equal to that provided in the original equipment.
(s)Disconnect batteries, negative connection(s) first. When reconnecting, connect positive connection first.
(t)Hydraulic systems, if so equipped, shall be checked for leaks, for condition of parts. Keep body and hands away from pin-holes or nozzles that eject fluids under high pressure. Use paper or cardboard, not hands, to check for leaks.
Owner’s Manual and Service Guide – PC & PCT Series
OPERATING INSTRUCTIONS
INITIAL CHECKLIST
Use the following checklist to inspect and prep your vehicle prior to initial use.
□Check for evidence of leaking fluids, i.e. battery acid, or gear oil.
□Check condition of tires and tire air pressure. Maximum 90 psi Cold; 60 psi recommended. (Pneumatic tires only).
□Check to ensure wheel lug nuts are tight.
□Check for tight/corrosion free battery connections
□Check for smooth operation of controls, switches, and brakes.
□Charge batteries.
□Confirm that the brake fluid is at the proper level
IDENTIFICATION
FIGURE 1
The product model number, serial number & year of manufacture is located on a silver label ( Figure 1), either on the front of the vehicle near the switches, on the underside of the plate where the seat is mounted or inside the motor compartment attached to a side panel.
Whenever you correspond with Wesley International regarding your vehicle, include this information.
CHARGING BATTERIES
Our Pack Mule electric vehicles come standard with an onboard charger. They also come available with a slide out battery system, in which case, no onboard charger is included. If your unit comes with the onboard charger, place the vehicle in a well-ventilated area and follow these steps to charge the battery:
1.Position the vehicle within reach of an electrical outlet.
2.Slide seat to the rear most position and tilt forward to open battery compartment.
3.Check all battery cells for proper acid level. Fluid should be above plates.
4.Plug in the charger AC line cord (Figure 2) which is already attached to the charger into a wall plug.
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CAUTION: |
Extension |
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cords must be a 3-wire |
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cord |
no |
longer |
than |
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30m |
(100’) at 10AWG |
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or 7.5m (25’) at 16 |
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AWG per UL guidelines. |
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Only |
connect |
ONE |
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charger to a single 15A |
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circuit or the circuit may |
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Figure 2 |
become overloaded. |
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Owner’s Manual and Service Guide – PC & PCT Series
VEHICLE CONTROLS, METERS, SWITCHES
The controls, meters and switches consist of:
Key Switch, Perma-Key Switch, or On/Off Switch
FWD/REV Directional Selector Switch
Battery Discharge Indicator (BDI)
Headlight / Tail Light Switch (Optional)
Parking Brake
Speed Control Pedal
Brake Pedal
Horn Button
Seat Presence Sensor Switch
Foot Presence Switch (Optional)
Key Switch: For vehicles equipped with a key switch (Figure 3), the vehicle only operates when the key is in the switch. It has two positions – run and off.
Key Switch
FIGURE 3
Perma-Key Switch (Optional): An optional Perma-Key switch is available to replace the standard key switch. It works the same way, but eliminates the need for a separate key that may get lost. It has three positions – run, off, and charge only.
On/Off Rocker Switch (Optional): An optional 2 position on/off Rocker switch is available to replace the standard key switch. (Figure 4).
On/Off Switch
FIGURE 4
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OPERATING INSTRUCTIONS
WARNING
To prevent unexpected vehicle movement or unauthorized use, always turn the key switch to the OFF position and remove key when the vehicle is not in use
Programmable Security Switch (Optional): SAFE-T-
LOCK™ is a programmable code switch,( Figure 5), which prevents unauthorized use of the vehicle.
It is offered as an option, part number EV-E901. The SAFE-T- LOCK switch is installed in lieu of the standard switch to control access and operation of the vehicle within the customer’s premises. It can be pre-installed at time of order, or purchased separately to upgrade existing vehicles.
FIGURE 5
The STL1000 switch allows plant and facility managers to input up to 99 different users/drivers to track vehicle usage. If 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 fourto eight-digit personal access code and a separate supervisor user menu programs the unit. The switch will provide the last user ID code when prompted by the supervisor. In operation, only users with active ID codes can operate the vehicle, virtually eliminating all unauthorized use, the company said.
The switch operates in a voltage range from 9 to 120 volts DC and is enclosed in an IP65 rated housing. Two internal LEDs indicate operational status - red indicates an error or lock mode and green indicates key press or touch is active. The unit also provides user feedback with key beep and error tones.
Step-by-Step Programming Instructions:
1 – Log onto the Supervisor Mode. Press 0 0 1 2 3 4 ENTER. Red and Green LED flashes along with an up tone beep indicate you are in the Supervisor Mode and ready to enter a Supervisor Mode menu.
Note: As you enter each Supervisor Mode menu, the number of Red LED flashes will correspond to the menu number. For example, one Red LED flash for menu 1, two Red LED flashes for menu 2, etc.
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.
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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
e use 5 4 3 2 1. Press 1, ENTER. (This puts you in the Change User PIN Menu.) Note that the switch will open when you go into this menu.
Note: The User has 1 minute after logging on the User Mode to use menu 1 before the menu function is locked out until the next User log on.
Press 5 4 3 2 1 ENTER, again press 5 4 3 2 1 ENTER. The switch will indicate that the new PIN has been accepted.
6 – Use the new PIN to close the switch. Press 0 1 5 4 3 2 1 ENTER. The switch will close. Press ENTER to open the switch and go out of User Mode. (Since this is an example, you may want to set the PIN for User location 01 back to the 1 2 3 4 default.)
7 – Log back onto the Supervisor Mode to change the Supervisor PIN. Press 0 0 1 2 3 4 ENTER. Press 1 ENTER to go into the Change Supervisor PIN Menu. The red LED will flash once. Now just you did in the User Mode, put the new PIN in twice and enter each time. Example: Press 5 4 3 2 1 ENTER, again 5 4 3 2 1 ENTER. The switch will give an indication that the PIN was changed.
Owner’s Manual and Service Guide – PC & PCT Series
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