Wesley BC-6200-8SA User Manual
SEPT 2013
OWNER’S MANUAL
AND SERVICE GUIDE
INDUSTRIAL ELECTRIC VEHICLE
Owner”s Manual and Service Guide – BCG Series
BCG-SERIES
FOREWARD
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.
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:
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/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 BCG 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.
Owner’s Manual and Service Guide – BCG 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
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
Battery Care.................................................................................................................................................................................. 20
Electrolyte Levels .......................................................................................................................................................................... 21
Battery Watering System .............................................................................................................................................................. 21
Cleaning Batteries ........................................................................................................................................................................ 21
Battery Replacement .................................................................................................................................................................... 21
Lifting the Vehicle ......................................................................................................................................................................... 22
Lubrication .................................................................................................................................................................................... 22
Brakes .......................................................................................................................................................................................... 23
Tires and Wheels .......................................................................................................................................................................... 23
COMPONENTS - ELECTRICAL ............................................................................................................................................................. 24
Basic Electrical Components ........................................................................................................................................................ 25
Special Order Onboard Battery Charger ....................................................................................................................................... 26
Motor ............................................................................................................................................................................................ 28
Controller ...................................................................................................................................................................................... 28
3 Owner’s Manual and Service Guide – BCG Series
Battery Discharge Indicator (BDI) ................................................................................................................................................. 43
Speed Control Pedal ..................................................................................................................................................................... 43
Solenoid ........................................................................................................................................................................................ 43
Parts List – Electrical .................................................................................................................................................................... 44
Parts List – Available Options ..................................................................................................................................................... 455
COMPONENTS - MECHANICAL .......................................................................................................................................................... 46
Parts List – Front Wheel Steer Assembly ..................................................................................................................................... 46
Hitch Options…………………………………………………………………………………………………………………………………..47
Owner’s Manual and Service Guide – BCG Series 4
INTRODUCTION
Thank you for choosing a Pack Mule Industrial Electric Vehicle, proudly built by Wesley International in the USA. At Wesley
International, we are committed to providing you the best quality product backed by exceptional customer service. This owner’s
manual and service guide is provided to help you get the most out of your new vehicle, for many years to come.
RECORD YOUR PRODUCT INFOR MATION
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! And it will entitle you 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
what you need, we are always ready and willing to help. Just email us at info@wesleyintl.com or call
(800) 241-2869 or (404) 292-7441.
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
5 Owner’s Manual and Service Guide – BCG 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
OPER ATOR 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.
.
Owner’s Manual and Service Guide – BCG Series 6
WARNING
WARNING
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.
Always insulate any tools used within the battery area in order to prevent sparks or battery
explosion caused by shorting the battery terminals or associated wiring.
Be sure to check the polarity of each battery terminal and be sure to rewire the batteries correctly. Never install a wire instead of a
proper fuse, even for a temporary fix. It may cause extensive damage and possible fire. Do not use a screwdriver or other metal
object to remove fuses. Doing so may cause an electrical short and damage the system. Do not modify or tamper with any part of
the operating or speed control systems. All inspections and adjustments must be made by a qualified technician.
Always support the vehicle using wheel chocks and safety stands. Never get under a vehicle that is supported by a jack. Lift the
vehicle in accordance with the instructions in this manual.
Always test drive the vehicle after any repairs or maintenance in a safe area free of any other vehicles or pedestrians.
VENTILATIO N
Hydrogen gas is generated in the charging cycle of batteries and is explosive in concentrations
as low as 4%. Because hydrogen gas is lighter than air, it will collect in the ceilings of buildings
and therefore, proper ventilation is required. Five air exchanges per hour is considered the
minimum ventilation required.
Always use a dedicated circuit for each battery charger. Do not permit other appliances to be plugged into the receptacle when the
charger is in operation.
7 Owner’s Manual and Service Guide – BCG 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
6.1 Introduction
6.1.1 Like other machines, carriers can cause injury if
improperly used or maintained. Part II contains broad safety
practices applicable to carrier operation. Before operation,
the user shall establish such additional specific safety
practices as may reasonably be required for safe operation.
6.1.2 Premise review — The user shall periodically
review their premises, and as conditions warrant, identify
areas where carriers should not be operated and to identify
possible hazards such as the following examples:
(a) Steep Grade — In areas where steep grades exist,
carrier operation should be restricted to the designated
vehicle’s pathways where possible, and shall be identified
with a suitable warning giving the following information:
“Warning, steep grade.”
(b) Wet Areas — Wet areas could cause a carrier to lose
traction and could affect steering, stability and braking.
(c) Sharp Turns, Blind Spots, Bridge Approaches —
Sharp turns, blind spots, bridge approaches, and other
potentially hazardous areas shall be identified with a suitable
warning to the operator of the nature of the hazard and
stating the proper precautions to be taken to avoid the
hazard.
(d) Loose Terrain — Loose terrain could cause a carrier
to lose traction and could affect steering, stability, and
braking.
6.2 Operation
Experience has shown that carriers, which comply with the
provisions, stated in paragraphs 9.4, 9.5, and 9.6 are stable
when properly operated and when operated in accordance
with specific safety rules and practices established to meet
actual operating terrain and conditions. However, improper
operation, faulty maintenance, or poor housekeeping may
contribute to a condition of instability and defeat the purpose
of the standard. Some of the conditions which may affect
stability are failure of the user to follow safety practices; also,
ground and floor conditions, grade, speed, loading, the
operation of the carrier with improper loads, battery weight,
dynamic and static forces, and the judgment exercised by
the carrier operator.
(a) The user shall train carrier operators to adhere
strictly to the operating instructions stated in this Standard.
(b) The user shall survey specific operating conditions
and environment, and establish and train carrier operators to
comply with additional, specific safety practices.
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 affect the capacity,
stability, or safe operation of the carrier, shall be made
without the prior written approval of the original carrier
manufacturer or a successor thereof. When the carrier
manufacturer or its successor approves a modification or
alteration, appropriate changes shall be made to capacity
plates, decals, tags, and operation and maintenance
manuals.
6.3.3 As required under paragraphs 6.3.1 or 6.3.2, the
manufacturer shall be contacted to secure new nameplates,
warnings, or instructions, which shall then be affixed in their
proper place on the carrier.
6.3.4 In the event that the carrier manufacturer is no
longer in business and there is no successor in interest to
the business, the user may arrange for a modification or
alteration to a carrier, provided however, the controlling party
shall:
(1) Arrange for the modification or alteration to be
designed, tested, and implemented by an engineer(s) expert
in carrier(s) and their safety;
(2) Maintain a permanent record of the design, test(s),
and implementation of the modification or alteration;
(3) Make appropriate changes to the capacity plate(s),
decals, tags, and operation and maintenance manuals;
(4) Affix a permanent and readily visible label on the
carrier stating the manner in which the carrier has been
modified or altered together with the date of the modification
or alteration, and the name of the organization that
accomplished the tasks.
6.4 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.
Owner’s Manual and Service Guide – BCG Series 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.
6.5 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 use 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.
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
Only persons who are trained in the proper operation of the
carrier shall be authorized to operate the carrier. Operators
shall be qualified as to visual, auditory, physical, and mental
ability to safely operate the equipment according to Section
7, all other applicable parts of this Standard and the
operators’ manual.
7.2 Personnel and Burden Carrier Operators’ Training
7.2.1 The user shall conduct an operators’ training
program.
7.2.2 Successful completion of the operators’ training
program by the operator shall be required before operation
of the carrier. The program shall be presented in its entirely
to all-new operators and not condensed for those claiming
previous experience.
7.2.3 The 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.
9 Owner’s Manual and Service Guide – BCG Series
INDUSTRY STANDARDS
7.3 Personnel and Burden Carrier Operator
Responsibility
7.3.1 General Operator Responsibility
7.3.1.1 Read and follow operators’ manual.
7.3.1.2 Do not operate carrier under the influence of drugs
and alcohol.
7.3.1.3 Safeguard the pedestrians at all times. Do not drive
carrier in a manner that would endanger other persons.
7.3.1.4 Riding on the carrier by persons other than the
operator is authorized only on personnel seat(s) provided by
the manufacturer. All parts of each person’s body shall
remain within the plan view outline of the carrier.
7.3.1.5 When a carrier is to be left unattended, stop the
carrier, apply the parking brake, stop the engine or turn off
power, turn off the control or ignition circuit, and remove the
key if provided. Additionally, for electric carriers, the forward
and reverse directional controls, should be neutralized if a
means is provided. Block the wheels if the carrier is on an
incline.
7.3.1.6 A carrier is considered unattended when the
operator is 7.6m (25 ft) or more from the carrier which
remains in his view, or whenever the operator leaves the
carrier and it is not within his view. When the operator is
dismounted and within 7.6m (25 ft) of the carrier still in his
view, he still must have controls neutralized, and the parking
brake(s) set to prevent movement.
7.3.1.7 Maintain a safe distance from potential hazards,
such as edges of ramps and platforms.
7.3.1.8 Use only approved carriers in hazardous locations,
as defined in the appropriate safety standards.
7.3.1.9 Report all accidents to the user.
7.3.1.10 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 traffic regulations, including authorized
speed limits. Under normal traffic conditions keep to the
right. Maintain a safe distance, based on speed of travel,
from a carrier or vehicle ahead; and keep the carrier under
control at all times.
7.3.2.2 Yield the right of way to pedestrians, ambulances,
fire trucks, or other carriers/vehicles in emergency situations.
7.3.2.3 Do not pass another carrier or vehicle traveling in
the same direction at intersections, blind spots, or at other
dangerous locations.
7.3.2.4 Keep a clear view of the path of travel, observe
other traffic and personnel, and maintain a safe clearance.
7.3.2.5 Slow down or stop, as conditions dictate, and
activate the sound-producing warning device at cross aisles
and when visibility is obstructed at other locations.
7.3.2.6 Ascend or descend grades slowly.
7.3.2.7 Avoid turning, if possible, and use extreme caution
on grades, ramps, or inclines; normally travel straight up and
down.
7.3.2.8 Under all travel conditions the carrier shall be
operated at a speed that will permit it to be brought to a stop
in a safe manner.
7.3.2.9 Make starts, stops, turns, or direction reversals in a
smooth manner so as not to shift the load, endanger
passengers, or lose control of the carrier.
7.3.2.10 Do not operate carrier in a dangerous manner.
7.3.2.11 Slow down when approaching, or on, wet or
slippery surfaces.
7.3.2.12 Do not drive carrier onto any elevator unless
specifically authorized to do so. Approach elevators slowly,
and then enter squarely after the elevator car is properly
leveled. Once on the elevator, neutralize the controls, shut
off power, and set parking brakes. It is advisable that all
other personnel leave the elevator before a carrier is allowed
to enter or exit.
7.3.2.13 Avoid running over loose objects, potholes, and
bumps.
7.3.2.14 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
7.3.3.1 Refer to operators’ manual for loading instruction.
7.3.3.2 Handle only stable and safely arranged loads.
When handling off-center loads, which cannot be centered,
operate with extra caution.
7.3.3.3 Handle only loads within the capacity of each cargo
area of the carrier as specified by the manufacturer.
7.3.3.4 Avoid material loads exceeding the physical
dimensions of the carrier or as specified by the carrier
manufacturer.
Owner’s Manual and Service Guide – BCG Series 10
INDUSTRY STANDARDS
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 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.
(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.
11 Owner’s Manual and Service Guide – BCG Series
OPERATING INSTRUCTIONS
On/Off Switch
FIGURE 1
Key Switch
INITIAL CHECK LIST
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 that all battery connections are tight/corrosion
free
□ Check for smooth operation of controls, switches, and
brakes.
□ Charge batteries.
IDEN TIFICATION
The product model number, serial number, and 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, be sure to include
this information.
CHAR GIN G BATTERIES
The BCG Series electric vehicles come standard with an
Industrial battery. Industrial batteries are charged with rapid
chargers that normally are hard wired into the plant electrical
system. No onboard charger is provided. However, we will
accept special orders that include an onboard charger.
When charging, follow these steps to charge the battery:
1) Position the vehicle within reach of the external
charger cord.
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) Unplug the battery from the vehicle and plug it into
the externally mounted charger using the cord from the
external charger.
CAUTION: Onboard chargers require extension cords that
are 3-wire cord no longer than 30m (100’) at 10AWG or 7.5m
(25’) at 16 AWG per UL guidelines. Only connect ONE
onboard charger to a single 15A circuit or the circuit may
become overloaded.
VEHICLE CO NTR OLS, 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
2), the vehicle only operates when the key is in the switch. It
has two positions – run and off.
FIGURE 2
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 3).
Owner’s Manual and Service Guide – BCG Series 12
.
FIGURE 3
WARNING
OPERATING INSTRUCTIONS
FIGURE 4
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 4), which
prevents unauthorized use of the vehicle. It is offered as an
option, part number EVE901. 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 preinstalled at time of order, or
purchased separately to
upgrade existing vehicles.
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 four- to eight-digit personal access
code and a separate supervisor user menu programs the
unit. The switch will provide the last user ID code when
prompted by the supervisor. In operation, only users with
active ID codes can operate the vehicle, virtually eliminating
all unauthorized use, the company said.
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
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.
13 Owner’s Manual and Service Guide – BCG Series
WARNING
NOTE
OPERATING INSTRUCTIONS
Directional Switch
8 – Go out of Menu 1. Press CE. Press CE again to Log Off
the Supervisor Mode.
9 – Check out the new Supervisor PIN. Press 0 0 5 4 3 2 1
ENTER. You should be in Supervisor Mode. You can now go
to any menu by pressing the menu number and ENTER.
Remember: This is an example. You should change your
Supervisor PIN to one known only to you.
10 – Determine Last user. While in Supervisor Mode press 3
ENTER. This places you in the Last User Menu as indicated
by three red LED flashes. Press ENTER again. The LED
flashes will indicate the last user. The Green LED is for the
10’s digit. The Red LED is for the 1’s digit. Example 1: A
single Red LED flash indicates User 01 last operated the
vehicle. Example 2: Two Green flashes and three Red
flashes would indicate User 23 last operated the vehicle.
Press CE to leave the menu.
11 – Enable or Disable Maintenance Alarm. Press 4 ENTER.
There will be four red LED flashes. Press ENTER again. If
the Green LED flashes, the alarm is enabled. Press ENTER
again and the Red LED will flash showing the alarm to be
disabled. Press ENTER again and the Green LED will flash
showing the alarm to be again enabled.
12 – Listen to the maintenance alarm. While in Menu 4 press
1 ENTER. The maintenance alarm will sound. Press CE to
leave the menu. Press CE again to Log Off the Supervisor
Mode.
Note: If the switch is left unattended in Supervisor mode, it
will automatically exit the mode after approximately one
minute.
13 – If you are unable to get into the Supervisor mode after
trying either the default PIN or a newly assigned PIN, go
back to Step 1 and reset the switch.
If all else fails or if you have questions about programming or
installing the SAFE-T-LOCK, call Tech Support at 1-800241-2869.
Directional Switch: The directional rocker or toggle switch
is used to place the vehicle in one of three operating modes
– forward, reverse, or neutral. (Figure 5) shows a rocker
directional switch.
The directional switch MUST be in
NEUTRAL (center) position BEFORE
selecting vehicle “ON” or a “Static Return
to Off” (SRO) error code will be generated by the motor
controller. The vehicle is temporarily immobilized as a
standard safety feature. (If your vehicle is equipped with the
Optional Foot Presence Switch and the unit is already turned
on and in neutral position, the foot presence switch MUST
be engaged before the directional switch is placed in forward
or reverse mode, or the same error code will be displayed
and the vehicle temporarily immobilized.) If this error code is
displayed, return the directional switch back to neutral,
ensure the foot presence switch is engaged, and then switch
the directional Switch to the desired forward or reverse
position and the vehicle will operate.
FIGURE 5
To prevent unexpected vehicle
movement, always place the
directional switch in the
NEUTRAL position when
leaving the vehicle.
Battery Discharge Indicator (BDI): The battery discharge
indicator, (Figure 6), communicates directly with the onboard
controller and provides information on various system
parameters, such as battery state-of-charge, operating hours
(on some models), or maintenance status including error
codes.
FIGURE 6
When powering on the vehicle, the BDI first indicates the
hours (Note: The controller is programmed to indicated
traction hours, which is the time that the motor is engaged
and the vehicle is moving. The controller can be
programmed to display “key-on” hours which records time
that the key switch is in the on position, regardless of
whether it is moving or not). It then cycles through to the
state of battery charge, measured in percent charge
remaining. If there are any faults recorded by the controller,
the BDI will display an error code and the LED by the tool
wrench symbol will illuminate.
Owner’s Manual and Service Guide – BCG Series 14
OPERATING INSTRUCTIONS
Headlight/Taillight Switch
Headlight / Tail-Light and Switch (Optional): Some
vehicles may include the headlight and/or tail-light (Figure 7)
option. In which case, there will also be a rocker switch to
turn the lights on or off. (Figure 8).
Brake Pedal: The brake pedal, Figure 10, is located to the
left of the accelerator pedal and is the smaller of the two.
Applying pressure on the brake pedal will slow the vehicle
down in addition to the motor braking. If driving down an
incline, the brake pedal should be used to control the speed.
FIGURE 7
FIGURE 8
SPEED CONTROL PEDAL:
The speed control pedal, (Figure 9) is located to the right of
the brake pedal. It controls the speed of the vehicle and is
operated with the right foot like the accelerator of an
automobile. Depressing the pedal starts the motor.
Releasing the pedal stops the motor. Reverse speed is half
of forward speed.
FIGURE 10
The brake pedal has a brake lock feature which can lock the
brake pedal into the down position (Figure 11), thus acting
as a parking brake. Simply push the brake pedal all the way
down while pushing at the bottom edge of the brake pedal.
This will engage the black pedal lock to latch onto the body
frame, retaining the brake pedal in the engaged position.
To release, simply push the top edge of the brake pedal and
the brake pedal will disengage and be free to move to its
disengaged position (Figure 12).
FIGURE 11 FIGURE 12
FIGURE 9
15 Owner’s Manual and Service Guide – BCG Series
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