Pack Mule PC NXG Series, Manual

Page 1: ...INDUSTRIAL ELECTRIC VEHICLE PC NXG and PCT NXG Series April 2017 ...

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Page 3: ... attached to the side of the motor compartment See page 5 for the location of the vehicle identification plate Register Your Pack Mule 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 inf...

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Page 5: ...p 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 ...

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Page 7: ...version of the manual go to the Pack Mule web site 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 Di...

Page 8: ...etails 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 Instrument Panel On Off Switch Forward Reverse Con trol and Smart View Display p 5 Motor Compartments Beneath the remova...

Page 9: ...erating the vehicle Read understand and observe all labels affixed 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 re quires excessive pressure Do not park or operate the vehicle near flamma ble objects or in a flammable or hazardous envi ronment Use only nece...

Page 10: ...driver 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 sys tems All inspections and adjustments must be made by a qualified technician Use a dedicated circuit for each battery charger and do not plug other appliances into receptacles on the circuit while the batteries are char...

Page 11: ...ED 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 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 over loaded Figure 3 The AC c...

Page 12: ...ot 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 off 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 Ad ditional mechanical and regenerative braking is en gaged using the brake pedal Drive ...

Page 13: ...e 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 di rectional switch to the neutral position 4 Turn the vehicle on by turning the Off 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 di...

Page 14: ...ble 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 Switch in OFF position if leav ing vehicle Comments To prevent unexpected movement on start up make certain that the directional switch is in the NEUTRAL center posit...

Page 15: ...t 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 infla tion may reduce tire life and adversely affect vehicle handling It may also lead to sudden tire failure resulting in a loss of vehicle control 3 A hydrometer measuring the specific gra...

Page 16: ...rge 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 Off position all electrical accessories are off 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 th...

Page 17: ...safe way to maintain precise bat tery electrolyte levels Cleaning Batteries For efficient operation the battery tops and termi nals should be kept clean The tops should be kept free of dirt and debris Clean the batteries using a solution specifically for mulated to neutralize battery acid deposit or a solu tion of sodium bicarbonate baking soda and water Mix cup 60 mL of sodium bicarbonate with 1 ...

Page 18: ... vehicle on unlevel or unstable sur faces When lifting the vehicle to jack stands al ways lift and secure the front of the vehicle first If the rear of the vehicle is lifted first the front may become unstable Soft Solid Solid Non Marking off white Although all of these should be inspected periodi cally only the pneumatic tires require maintenance Make certain that the tire pressure is maintained ...

Page 19: ...ttery could not be trickle charged up to minimum voltage Check for shorted or damaged cells Reset the charger by interrupting the AC for at least 15 seconds 5 Charger shutdown due to high internal temperature Ensure sufficient cooling airflow Reset the charger by interrupting the AC for at least 15 seconds 6 Internal charger fault Reset the charger by interrupting the AC for at least 15 seconds If...

Page 20: ... 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 con nector or uninsulated battery terminals Disconnect the AC su...

Page 21: ...ammable Parameters Programmable parameters allow the vehicle s per formance 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 effect on vehicle behavior and can be adjusted with the available hand held programmer Acceleration Rate Decelerat...

Page 22: ...rakes 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 1 3 2 4 5 6 7 A B C D E E D C A B B M E 1 2 3 4 10...

Page 23: ...5012 1 Battery electrolyte Low Level de tected Check battery electrolyte level 5 F15013 1 Battery electrolyte Low Level de tected and cut back Check battery electrolyte level 5 F15014 1 6 F16001 1 Warning level throttle fault Used on Renault Twizy Check throttle wiring and installation 6 F16002 1 Throttle appears to be stuck This fault will clear if throttle starts to work again Check throttle wir...

Page 24: ...acitor voltage is greater than rated maximum voltage for longer than protection delay Charge battery 7 F17006 1 Battery voltage is less than rated min imum voltage for controller for longer than 1s Charge battery 7 F17007 1 Battery voltage is greater than rated maximum voltage for longer than 1s Charge battery 7 F17008 1 Capacitor voltage is greater than rated maximum voltage for longer than 1s Ch...

Page 25: ...ncoder 11 F11102 1 SinCos Encoder Min Max values are heading towards a voltage rail or converging together Thermal or mechanical variation is causing the sincos encoder to deviate from the cold factory commissioned values 11 F11103 1 A fault ride through event has been encounter but operation is allowed to continue although the system may be derated None 11 F11104 1 The open loop V f induction mot...

Page 26: ...e switches have been inactive simul taneously for greater than 200 ms Check vehicle wiring and reset switches 2 F22003 2 FS1 active for user configurable delay without a direction selected Deselect FS1 2 F22004 2 Any drive switch active at power up Deselect all drive switches 2 F22005 2 FS1 active after a direction change and FS1 recycle function enabled Deselect FS1 2 F22006 2 Inch switch active ...

Page 27: ...priate action 10 F20101 2 One or more configured RPDOs not received within 3s at start up or 500ms during normal opera tion Check status of all nodes on CANbus Check PDOs on all CANbus nodes 12 F22101 2 12 F22102 2 12 F22103 2 Vehicle application subsystem is not receiving control or status information Check CANbus wiring and configuration of J1939 signal mapping 12 F22104 2 Controller failed to r...

Page 28: ...ot received within 3s at start up or 500ms during normal opera tion Check status of all nodes on CANbus 11 F31101 3 Controller is unable to control a current in the field winding Check field is wired to correct terminals 11 F31102 3 The motor control protection subsystem unexpectedly disabled the PWM Check for the presence of other faults that may indicate root cause of the problem 12 F32101 3 12 ...

Page 29: ...ssage received from non Sevcon node and anonymous EMCY level is set to 3 Check status of non Sevcon nodes on CANbus 1 F41001 4 EEPROM or flash configuration data corrumpted and data cannot be recovered 1 F41002 4 VPDO mapped to non existant or invalid object Check all VPDO mappings 1 F41003 4 At least one configuration object is out of range Set configuration object to valid value Out of range obj...

Page 30: ...e 5V at power up Check power wiring 7 F47003 4 The voltage applied to the KL 15 30 is above the controller rated maximum Check KL 15 30 voltage 8 F48001 4 Controller heat sink has reached citical high temperature and has shut down Allow controller to cool down to normal operating temperatures 11 F41101 4 Encoder wire off is detected Check encoder wiring 11 F41102 4 Motor current exceeded control l...

Page 31: ...in con figured time out Check status of all nodes on CANbus 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 softwar...

Page 32: ...004 5 MOSFET IGBT s c detection on M1 bottom devices Check motor wiring Check controller condition 3 F53005 5 MOSFET IGBT s c detection on M2 top devices Check motor wiring Check controller condition 3 F53006 5 MOSFET IGBT s c detection on M2 bottom devices Check motor wiring Check controller condition 3 F53007 5 MOSFET IGBT s c detection on M3 top devices Check motor wiring Check controller condi...

Page 33: ...h 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 im proper loads battery weight dynamic and static forces and the judgment exercised by the carrier op erator a The user shall train carrier operators to adhere strictly to the operating instructions stated in this Standard b The user shall...

Page 34: ...d 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 combus tion engines is used in enclosed areas the atmo sphere shall be maintained within limits specified in the American Conference of Governmental Indus trial Hygienists publication Threshold Limi...

Page 35: ...edges of ramps and platforms 7 3 1 8 Use only approved carriers in hazardous locations as defined in the appropriate safety stan dards 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 unat tended such that they block or obstruct fire aisles access to stairways or fire equipment 7 3 1 12 Only operate carrier while wi...

Page 36: ...eak 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 elec trolyte 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 ...

Page 37: ...l be kept clean to minimize hazards and facilitate detection of components needing ser vice q Modifications and additions which affect capac ity 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 labe...

Page 38: ...eep 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 indicat ing the location is ready to be added or ...

Page 39: ...ated 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 EN TER again If the Green LED flashes the alarm is en abled Press ENTER again and the Red LED will flash showing the alarm to be disabled Press ENTER again and the...

Page 40: ... 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 C Specifications ...

Page 41: ...er 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 Off Switch EV E017 Programmable Code Security Switch EV E901 Headlight Taillight Switch Rocker EV E155 Single LED Charge Status Plate EV ...

Page 42: ... 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 E...

Page 43: ...e 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 ...

Page 44: ...t 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 Was...

Page 45: ... 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 Cast...

Page 46: ...40 Appendix H Transaxle PC Series ...

Page 47: ...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 Shaf...

Page 48: ...Appendix I Transaxle PCT Series Series ...

Page 49: ... 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 ...

Page 50: ...E 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 ...