INDUSTRIAL ELECTRIC VEHICLE OWNER’S MANUAL AND SERVICE GUIDE BCG-SERIES SEPT 2013 Owner”s Manual and Service Guide – BCG 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.
TABLE OF CONTENTS INTRODUCTION ................................................................................................................................................................................ 5 SAFETY INFORMATION .................................................................................................................................................................... 6 Training ...........................................................................................................
Battery Discharge Indicator (BDI) ................................................................................................................................................. 43 Speed Control Pedal..................................................................................................................................................................... 43 Solenoid ....................................................................................................................................
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.
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. T RAINING Vehicle owners/lessees are responsible for instructing their personnel in its safe operation.
SAFETY INFORMATION Good common sense and prudent driving practices do more to prevent accidents and injuries than all of the warnings and instructions combined.
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.
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.
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.
INDUSTRY STANDARDS 7.3.4 Operator Carriers Care of Personnel and Burden 7.3.4.1 Read and follow operators’ manual. 7.3.4.2 At the beginning of each shift during which the carrier will be used, the operator shall check the carrier condition and inspect the tires, warning devices, lights, battery(s), speed and directional controllers, brakes, safety interlocks, and steering mechanism.
OPERATING INSTRUCTIONS I NITIAL C HECKLIST Use the following checklist to inspect and prep your vehicle prior to initial use. □ □ □ □ □ □ Check for evidence of leaking fluids, i.e. 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.
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-TLOCK™ is a programmable code switch,( Figure 4), which prevents unauthorized use of the vehicle. It is offered as an option, part number EVE901.
OPERATING INSTRUCTIONS the directional Switch to the desired forward or reverse position and the vehicle will operate. 8 – Go out of Menu 1. Press CE. Press CE again to Log Off the Supervisor Mode. 9 – Check out the new Supervisor PIN. Press 0 0 5 4 3 2 1 ENTER. You should be in Supervisor Mode. You can now go to any menu by pressing the menu number and ENTER. Remember: This is an example. You should change your Supervisor PIN to one known only to you. 10 – Determine Last user.
OPERATING INSTRUCTIONS 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.
OPERATING INSTRUCTIONS Horn and Horn button: The horn button is located at the top of the right side of the instrument panel. It is operated by the right hand. The horn (Figure 13) will not sound when the key or on/off switch is in the off position. F IGURE 15 Seat Presence Sensor Switch: The presence sensor switch is located under the seat ( Figure 16) and is designed to prevent operation of the vehicle unless a person is sitting down on the seat.
C OASTING OPERATING INSTRUCTIONS D RIVING Follow these steps to operate your Pack Mule vehicle: 1) 2) 3) 4) 5) 6) 7) 8) 9) Disconnect the battery charger. Unplug the battery from the external battery cord. Plug the battery back into the vehicle and lower the seat back into position. Check for correct tire inflation (pneumatic tires only). Inspect for fluid leaks. Ensure surrounding area is clear of all obstructions and everything properly stored and secured.
START UP CHECKLIST FOR INDUSTRIAL TRUCKS All industrial trucks that are used within <> are required to be inspected each day prior to use. TRUCK NO.
MAINTENANCE INSTRUCTIONS M AINTENANCE S CHEDULE Safe trouble-free operation of your electric vehicle depends on regular and proper preventive maintenance. The following chart is a guide for servicing your Pack Mule electric vehicle.
WARNING MAINTENANCE INSTRUCTIONS R OUTINE M AINTENANCE Before performing any CAUTION maintenance or repair work, isolate the batteries from the motor and electronics by opening the circuit breaker in (Figure 17). Simply push the red push button until the red side lever fully opens (Figure 18). To close the circuit breaker, simply push the red side lever to its original closed position.
MAINTENANCE INSTRUCTIONS 4) 5) During shipment or prolonged storage the electrolyte levels may fall below the separator protector. Only after a complete discharge and charge cycle, check and keep electrolyte level above separator and 1/8” (3.175mm) below vent well. Add approved water only when required and never add acid. Keep battery top clean, dry and vent caps tightly in place. 6) Keep open flame and metal objects away from battery top.
MAINTENANCE INSTRUCTIONS L IFTING THE V EHICLE L UBRICATION Proper lubrication will ensure maximum years of trouble free service from your Pack Mule. Illustration of vehicle’s lubrication points WARNING To prevent possible injury or death resulting from a vehicle falling from a jack, be sure the vehicle is on a firm and level surface. Never go beneath a vehicle while it is supported by a crane or jack. Use jack stands and test the stability of the vehicle.
MAINTENANCE INSTRUCTIONS Rear Axle: Check fluid level in the rear axle per the recommended maintenance schedule. The rear axle is provided with a fluid level check/fill plug (Figure 23) located at the bottom of the differential. With the vehicle on level ground, clean the area around the check/fill plug and remove plug. The correct fluid level is just below the bottom of the threaded hole. If fluid levels are low, add as required until it starts to seep from the hole. Replace the check/fill plug.
MAINTENANCE INSTRUCTIONS Replacing Front Tires/Wheels: To remove and repair the front tires and/or wheels, complete the following steps: 1) 2) 3) 4) 5) Remove the axle nut retaining clip. Lift the front of the vehicle as explained in the “Lifting the Vehicle” Section. Loosen the axle nuts and remove the entire wheel, hub and axle assembly from front fork. Remove the lug nuts and remove the wheel from the axle assembly. Reinstall the repaired or replacement tire by reversing the above sequence.
B ASIC E LECTRICAL C OMPONENTS Your Pack Mule electric vehicle is purposely designed around the “Keep it Simple” principal. Our philosophy at Wesley International is to engineer products with only the critical components necessary to meet the demanding industrial environment, cutting out any unnecessary “bells and whistles” which only increase ownership costs.
SPECIAL C HARGER ORDER O NBOARD B ATTERY This section is included in case your unit has the optional onboard Delta-Q Battery Charger ( Figure 25). The onboard charger is air cooled, eliminating any moving parts for increased reliability and life span. Because of this, the mounting location has been designed to optimize air flow and it is important that this air flow is not inhibited in any way. Regularly check the cooling fins to ensure they are free of dirt, dust, or other contaminants.
COMPONENTS - ELECTRICAL The optional charger Single-LED display, if included, would be located on the front panel, near the key-switch. LED Color Indication (following “Power-On Self Test”) Green 1) 2) 3) Solid: Charging complete. Charger in Maintenance Mode. Flashing: Short: <80% Charge Long: >80% Charge Amber Flashing: Reduced power mode: Low AC voltage or High internal charger temperature. Red Flashing: Charger error. Reset charger power and refer to trouble shooting instructions.
COMPONENTS - ELECTRICAL STANDARD M OTOR BCG Pack Mule Vehicles have industrial towing capacity because they use the Advanced Motor and Drives’ 4.2 KW AC Motor ( EV-E186) (Figure 26). C ONTROLLER The BCG Series electric vehicle is equipped with the Curtis model 1236 AC 350 amp controller (part # EV-E181) (Figure 27). This programmable controller is simple to install, efficient, and cost effective. The Curtis controller provides smooth precise control of motor speed and torque.
COMPONENTS - ELECTRICAL Controller Features Include: Interlock braking with load sensor to meet required braking distance without unnecessary harsh braking when carrying light loads Maintenance monitor responds to preset vehicle operating hours and drive hours as programmed by the OEM Two hour meters—total KSI-on hours and traction hours—and the associated maintenance timers are built into the controller BDI calculations performed within controller Estimates motor temperature based on field resist
Use the following cleaning procedure for routine maintenance: 1) Remove power by disconnecting the battery. 2) Discharge the capacitors in the controller by connecting a load (such as a contactor coil or a horn) across the controller’s B+ and B-terminals. 3) Remove any dirt or corrosion from the connector areas. The controller should be wiped clean with a moist rag. Dry it before reconnecting the battery.
COMPONENTS - ELECTRICAL Controller Wiring: Typical 1236 AC Motor Controller wiring configuration of BGC series vehicles. The interlock switch is a seat switch or foot switch and there is no emergency reverse.
Owner’s Manual and Service Guide – BCG Series 32
COMPONENTS - ELECTRICAL Fault Codes and Troubleshooting Chart: 33 Owner’s Manual and Service Guide – BCG Series
COMPONENTS - ELECTRICAL Fault Codes and Troubleshooting Chart: Owner’s Manual and Service Guide – BCG Series 34
COMPONENTS - ELECTRICAL Fault Codes and Troubleshooting Chart: 35 Owner’s Manual and Service Guide – BCG Series
COMPONENTS - ELECTRICAL Fault Codes and Troubleshooting Chart: Owner’s Manual and Service Guide – BCG Series 36
COMPONENTS - ELECTRICAL Fault Codes and Troubleshooting Chart: 37 Owner’s Manual and Service Guide – BCG Series
COMPONENTS - ELECTRICAL Fault Codes and Troubleshooting Chart: Owner’s Manual and Service Guide – BCG Series 38
COMPONENTS - ELECTRICAL Fault Codes and Troubleshooting Chart: 39 Owner’s Manual and Service Guide – BCG Series
COMPONENTS - ELECTRICAL Fault Codes and Troubleshooting Chart: Owner’s Manual and Service Guide – BCG Series 40
COMPONENTS - ELECTRICAL Fault Codes and Troubleshooting Chart: 41 Owner’s Manual and Service Guide – BCG Series
COMPONENTS - ELECTRICAL Fault Codes and Troubleshooting Chart: Owner’s Manual and Service Guide – BCG Series 42
COMPONENTS - ELECTRICAL B ATTERY D ISCHARGE I NDICATOR (BDI) The Curtis BDI (Figure 28 shows the 24/36V version) displays various system parameters, such as battery stateof-charge, operating hours or maintenance status from the Curtis motor controller. Features include: Attractive, easy-toread, 8 character dot matrix Liquid Crystal Display. • 6 LEDs -five green to indicate battery state-of-charge and one red to indicate that a fault has occurred.
COMPONENTS - ELECTRICAL P ARTS L IST – E LECTRICAL Part Part Number Key Switch, 3-position (standard) EV-E100 Key Replacement, set of 2 EV-E160 Directional Switch, 3 position Rocker EV-E156 Horn EV-E130 Horn Button EV-E047B BDI – 36 / 48 volt vehicles EV-E126 Circuit Breaker EV-E015-150A Solenoid, 4-terminal 36V EV-E064HD Solenoid, 4-terminal 48V EV-E204 HD 1 Amp Fuse EV-E015 1A Fuse Holder EV-E016 Motor Controller, AC EV-E181 -350 Motor, AC EV-E186 Pedal Assy Flush Mount EV-E52
COMPONENTS - ELECTRICAL P ARTS L IST – A VAILABLE O PTIONS Part Part Number 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-E808L Foot Presence Switch EV-E128 Battery Watering System – 36V GC135 EV-E900-2 Battery Watering System – 36V GC145 EV-E900-1 Battery Watering System – 48V FS8D EV-E900FX-310 Headlight – 12 -48 volt EV-E190 Headlight/Taillight/Brake light – 24 /
COMPONENTS - MECHANICAL P ARTS L IST – F RONT W HEEL S TEER A SSEMBLY Owner’s Manual and Service Guide – BCG Series 46
TRANSAXLE – EPLODED VIEW 47 Owner’s Manual and Service Guide – BCG Series
HITCHES Owner’s Manual and Service Guide – BCG Series 48
PROUDLY BUILT IN THE USA 49 Owner’s Manual and Service Guide – BCG Series
