Wesley Pack Mule User Manual
Pack Mule
Power Mule
Electric Utility Vehicle Owner’s Manual
for DC-Powered Vehicles
Effective May 22, 2009
Wesley International
3680 Chestnut Street
Scottdale, Georgia 30079
Phone (404) 292-7441 • Toll Free (800) 241-2869 • Fax (404) 292-8469
www.WesleyInternational.com
Table of Contents
Wesley’s Service Partnership With You ................................................................................................. 4
Vehicle Inspection Checklist .................................................................................................................. 5
Safety Instructions ................................................................................................................................ 6
Operating Instructions .......................................................................................................................... 9
Maintenance ........................................................................................................................................ 12
Basic Mechanical Components ............................................................................................................. 14
Electrical Components ......................................................................................................................... 15
Transaxle Maintenance and Repair ...................................................................................................... 16
Front Wheel Steering Assembly ........................................................................................................... 22
Accelerator Linkage Assembly ............................................................................................................ 23
Troubleshooting ................................................................................................................................... 24
Warranty ............................................................................................................................................ 28
EUV Owner’s Manual 2 May 22, 2009
Wesley’s Service Partnership With You
Introduction
Thank you for choosing a Wesley International electric utility vehicle. We are committed to delivering
excellent service before, during and after the sale. By following the operating and maintenance instructions provided in this manual, we can work together to ensure you get the best from your Pack Mule
TM
Power Mule
Record Your Product Information
Model #: Serial #:
Purchase Date:
product.
®
or
Register Your Product
PRODUCT REGISTRATION IS REQUIRED FOR WARRANTY COVERAGE. Complete and return
the enclosed warranty card immediately. See “Warranty” in this manual for coverage information.
Read This Manual
Before operating your new electric vehicle, read this manual to become familiar with the safety guidelines,
operating instructions and maintenance procedures.
If You Need Service
You will fi nd many answers to common problems in the Troubleshooting section. If do not fi nd an
answer there, we are always ready and willing to help you. Just e-mail us at info@WesleyIntl.com or call
800-241-2869.
Phone (404) 292-7441 • Toll Free (800) 241-2869 • Fax (404) 292-8469
Wesley International
3680 Chestnut Street
Scottdale, Georgia
www.WesleyInternational.com
EUV Owner’s Manual 2 May 22, 2009
4
Vehicle Inspection Checklist
After Delivery
Use the following checklist to inspect your vehicle upon delivery.
Item Yes No
1. Did you receive all accessories?
2. Did you open and inspect all accessories?
3. Are any accessories damaged?
4. Are there dents or cracks on the vehicle?
5. Are the tires in good condition and properly infl ated to 60 psi?
6. If you received an optional external battery charger, is the battery charger in good
condition?
7. Are the steering controls and front steering gears operating freely and properly?
IMPORTANT: Notify the carrier immediately of any damage that occurred during shipping. Call Wesley at
800-241-2869 for all other problems or questions.
Before Operating the Vehicle
Before operating the vehicle, make sure the:
tire pressure is at least 60 psi.
•
wheel lug nuts are tight.
•
all battery connections are tight.
•
EUV Owner’s Manual 2 May 22, 2009
5
Safety Instructions
Introduction
The responsibility for safety lies with four main groups: manufacturers, owners, operators and maintenance
personnel. As a manufacturer, our responsibility is to ensure that you are acquainted with the capabilities
of the vehicle and to recommend guidelines for safe operation based on the vehicle’s characteristics.
Training
Vehicle owners are responsible for instructing their personnel in its safe operation. Owners must explain
the vehicle’s characteristics, features and the operation of its controls. We strongly recommend that owners
fi rst become familiar with the conditions of the place where the vehicle will be operated in order to assess
their 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
•
A driving and operating test
•
Operator Qualifi cations
Operators should be selected based on their ability to safely operate the vehicle, including vision, hearing,
physical and mental capabilities. Operators must:
demonstrate a working knowledge of all controls.
•
understand all safety guidelines.
•
be able to properly drive and park the vehicle under 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 and Power Mule vehicles are designed for use on smooth surfaces in and around industrial
plants, warehouses, nurseries and greenhouses. They are not designed for use on public highways.
Driving
Follow these guidelines to safely drive the vehicle:
Read this manual before operating the vehicle.
•
Do not start the vehicle without checking the brakes fi rst.
•
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 fl ammable objects or in a fl ammable or hazardous
•
environment.
Use only necessary power.
•
Keep both hands on the steering wheel while operating the vehicle.
•
Accelerate and decelerate slowly.
•
EUV Owner’s Manual 2 May 22, 2009
6
Safety Instructions (cont’d)
Safety Guidelines (continued)
Driving (continued)
Exercise extreme caution when driving in reverse.
•
Keep arms and legs within the operator’s platform while driving.
•
Do not use the vehicle to push objects.
•
Perform all recommended maintenance procedures at the specifi ed intervals.
•
Do not operate in sand, gravel or snow.
•
Do not use the accelerator to hold the vehicle at a standstill on an incline.
•
Do not allow the tires to lose contact with the ground.
•
Do not overload the vehicle above its rated load or towing capacity.
•
Make sure the area of operation is clear of trash, litter and other foreign objects.
•
Proceed around low overhangs with caution. Be sure there is enough clearance for the operator’s head
•
and the ladder and/or backrest.
Never abruptly change direction.
•
Adjust speed according to the surface conditions.
•
Always drive directly up an incline; never across.
•
Remain in the operator’s position when operating the vehicle.
•
Do not exceed the designated passenger, load or towing capacity.
•
Loading and Unloading
Follow these guidelines when loading and unloading cargo:
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.
•
Be extremely careful carrying loads that extend beyond the vehicle’s deck.
•
Towing
Follow these guidelines when towing:
Turn the vehicle off when connecting to the equipment that will be towed.
•
Always use a properly installed hitch. (Optional hitches are available from Wesley International. Call
•
800-241-2869 to order.)
Do not exceed the maximum towing capacity.
•
Do not exceed 5 mph when towing.
•
EUV Owner’s Manual 2 May 22, 2009
7
Safety Instructions (cont’d)
Fuses
Follow these instructions when servicing the electrical system:
Never install a wire instead of the proper fuse, even for a temporary fi x. It may cause extensive damage
•
and possibly a fi re.
Do not use a screwdriver or other metal object to remove fuses. Doing so may cause an electrical short
•
circuit 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 qualifi ed technician.
Wheels and Tires
When replacing tires, make sure the new wheels and tires are equivalent in diameter, rim width, off-set
and load range rating to those you are removing. An incorrect size may adversely affect the wheel and
bearing life, braking and stopping capability, handling characteristics, ground clearance and body-to-tire
clearance.
General Safety Practices
Follow these instructions each time you service the vehicle:
Completely remove and secure the deck lid before checking any portion of the drive train,
•
batteries, etc.
Chock the wheels at all times.
•
Before returning the deck lid to its normal position, make sure the battery charging plug is discon-
•
nected from the receptacle, the battery-charging wires are securely tied and all tools removed before
operating the vehicle.
EUV Owner’s Manual 2 May 22, 2009
8
Operating Instructions
Vehicle Controls
Accelerator Pedal
Seated Vehicles: The accelerator pedal is located to the right of the brake pedal. It controls the speed of
the vehicle. It is operated with the right foot like the accelerator of an automobile.
Standing Vehicles: One pedal functions as the accelerator and the brake. The speed is proportionate to the
amount of pressure applied to the pedal. The vehicle brakes as pressure on the pedal is decreased.
Key Switch
The vehicle only operates when the key is in the switch. The switch (Part # EV-E100) has three positions:
run, off and charge only.
Function Key Position
Run Right
Off Center
Charge Only Left
Directional Switch
The directional switch (Part # EV-E035) is on the instrument panel. It has three positions: forward, reverse
and neutral.
Direction Switch Position
Forward Up
Reverse Down
Park/Neutral Center
WARNING
Be sure the vehicle has completely stopped before changing directions. Rapidly changing direction
while the vehicle is moving may cause the cargo to shift and possibly injure the operator and/or others.
Damage resulting from failure to operate the vehicle according to the instructions in this manual is not
covered by the warranty.
EUV Owner’s Manual 2 May 22, 2009
9
Operating Instructions (cont’d)
Charging
Place the vehicle in a well-ventilated area and follow these steps to charge the battery:
Remove the deck for battery ventilation.
1.
Check the battery’s water levels.
2.
Plug the charger cord into the wall receptacle and into the charger receptacle located on the rear of the
3.
vehicle.
Turn the key switch to the CHARGE position.
4.
Driving
Follow these steps to operate your Pack Mule or Power Mule vehicle:
Disconnect the battery charger.
1.
Remove the charger cord from the 120-Volt power outlet. Disconnect the charger cord from the charger
receptacle located on the rear of the vehicle. Ensure that the area is clear of all obstructions.
Turn the key switch to the ON position.
2.
Be sure that the direction switch is in the neutral position and the accelerator pedal is not depressed.
Insert the key into the ignition switch located on the instrument panel. Turn the key completely to the
right. The indicator light (BDI) located immediately above the ignition switch should come on. If not,
do not attempt to operate the vehicle.
Move the directional switch to the desired setting.
3.
The vehicle will not operate if the accelerator pedal is depressed and the directional switch is in the
middle or neutral position. (See “Key Switch” on page 8.)
NOTE: If the directional switch is left in the FORWARD or REVERSE position for 10 seconds or
more without depressing on the accelerator pedal, the delay safety feature engages, and the vehicle
will not move. The operator must turn the directional swith to the NEUTRAL position, and then back
to the desired direction to resume motion.
Press the accelerator.
4.
Depress the accelerator with your foot. The speed of the vehicle will be proportional to the amount
of pressure that is applied to the pedal. The controller regulates the speed, acting as an automatic
transmission.
Stopping.
5.
Standing Vehicles: Remove your foot from the accelerator pedal. The brake will automatically engage
upon releasing the accelerator.
Seated Vehicles: Press on the separate brake pedal.
EUV Owner’s Manual 2 May 22, 2009
10
Loading...