Pack Mule PC NXG Series User manual

INDUSTRIAL ELECTRIC VEHICLE
PC NXG and PCT NXG Series
April 2017

iii
Introduction
Thank you for choosing a Pack Mule Industrial Electric Vehicle, proudly built in the USA by Wesley Interna-
tional. Wesley International is committed to providing you with the best quality product and backing it with
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. For convenience, record your product information in the
space below and keep this information with the vehicle. The model and serial numbers can be found on the
vehicle identification plate 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 [email protected] or call [phone] or [phone]. We’re always glad to help.
Record Your Product Information
Model #:
Serial #:
Purchase Date:
Important
Product registration is required for warranty coverage.
Wesley International
3680 Chestnut Street
Scottdale, GA 30079
Phone [phone] • Toll Free [phone] • Fax [phone]
[email protected] • www.wesleyinternational.com

Contents
Safety Information.........................................................................................................3
Training ................................................................................................................................................3
Operator Qualifications ...........................................................................................................................3
Safety Guidelines.......................................................................................................................................3
Loading and Unloading............................................................................................................................3
Ventilation ................................................................................................................................................4
Towing ................................................................................................................................................4
Maintenance...............................................................................................................................................4
Operating Instructions .................................................................................................5
Before Putting Your Vehicle in Service .................................................................................................5
Vehicle Identification................................................................................................................................5
Charging Batteries ....................................................................................................................................5
Vehicle Controls, Meters, Switches.......................................................................................................5
Horn ................................................................................................................................................6
Accelerator/Brake ....................................................................................................................................6
Left-foot Presence Switch ......................................................................................................................6
Optional Equipment .................................................................................................................................6
The Smart View Display ...........................................................................................................................6
Driving the Pack Mule NXG..................................................................................................................... 7
Parking ................................................................................................................................................ 7
Driver Assist on Inclines........................................................................................................................... 7
Start-up 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 Safe-T-Lock Switch..........................................................................32
Appendix C: Specifications......................................................................................................................34
Appendix D: Components—Electrical ..................................................................................................35
Appendix D: Components—Electrical (cont.) .....................................................................................36
Appendix E: Rear End ...............................................................................................................................37
Appendix F: Front Axle .............................................................................................................................38
Appendix G: Floor Panel..........................................................................................................................39
Appendix H: Transaxle—SC Series ........................................................................................................ 40
Appendix I: Transaxle—SCT Series.........................................................................................................42

1
Please read this first:
When you receive your Pack Mule NXG vehicle, it’s important to visually inspect the machine for any dam-
age that may have occurred during shipping. If you find any shipping damage, have it noted on the carrier’s
bill immediately, specifically identifying the nature of the damage.
Keep this manual with the vehicle at all times. It provides operating and maintenance instructions, as well as
precautions for the safe operation of the vehicle. It is the responsibility of the owner, user, lessor or lessees to
ensure that the vehicle is used as intended.
Please read this entire manual to familiarize yourself with the safe operation of this vehicle, paying particular
attention to anything labeled Caution, Note, or Warning. See below for the graphic representation of these.
We also encourage you to read the industry standard operating and safety procedures in Appendix A.
Because of continuing product improvement, 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, 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 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 information in this manual.
The use of non-OEM (Original Equipment Manufacturer) parts may void the warranty.
Overfilling the batteries may void the warranties.
Notes, Cautions, and Warnings
Throughout this manual important information will be emphasized under one of the following headings.
Please pay special attention to this information.
This graphic indicates information regarding a condition that should be ob-
served.
This graphic indicates information regarding a condition that might result in
damage to the vehicle.
This graphic indicates information regarding a condition that might result in
severe injury or death.

2
Your Pack Mule PC NXG or PCT NXG Vehicle
Your Pack Mule NXG vehicle is powered by the industry-leading AC-Power system and has been config-
ured and outfitted according to your company’s requirements. It is also available in dierent models, each
designed to meet specific requirements. This manual covers the basics of each of the PC NXG or PCT NXG
systems; however, you may find dierences in the details 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/O Switch, Forward/Reverse Con-
trol, and Smart View Display (p. 5)
Motor Compartments
Beneath the removable cargo
deck are the motor (p. 15), the
charger (p. 13) and the motor
controller (p. 15).
Figure 1
The batteries (p. 10) are located under
the seat. To access the batteries, grasp
the seat back and tilt it forward.

3
Safety Information
This manual has been designed to help the owner/
operator operate the vehicle safely and according to
the procedures and standards for which the vehicle
was designed and intended for use. This section pro-
vides the essentials of safe operation. There is a more
thorough discussion in Appendix A: Industry Stan-
dards.
Training
Vehicle owners are responsible for making certain
that appropriate personnel are fully trained in the safe
operation of the vehicle and understand its charac-
teristics and features, the operation of its controls,
and safe driving practices. Those responsible for
training operators should first become familiar with
the conditions of the place where the vehicle will be
operated in order to assess its eect on safe oper-
ation. Training should occur under the conditions
of the operating environment while adhering to the
safety guidelines and should include:
• Safety guidelines
• Safely operating vehicle in the work environ-
ment.
• Operation of all controls
• Safe driving practices
• A driving and operating test
Operator Qualifications
Operators should be selected based on their ability
to safely operate the vehicle, including vision, hear-
ing, physical and mental capabilities. Operators must:
• Demonstrate a working knowledge of all con-
trols
• Understand all safety guidelines
• Be able to properly drive and park the vehicle un-
der usual working conditions
• Know how to properly load, unload and tow car-
go
• Recognize maintenance problems
Safety Guidelines
All Pack Mule vehicles are designed for use on
smooth surfaces in and around industrial plants,
warehouses, nurseries and greenhouses. They are
not intended for use outdoors, up and down steep
grades, or on public roads and highways.
Follow these guidelines for safe vehicle operation:
• Read this manual before operating the vehicle
• Read, understand and observe all labels axed 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 necessary power
• Keep both hands on the steering control while
operating the vehicle
• Accelerate and decelerate slowly and in a con-
trolled manner
• Always reduce speed when operating on poor
terrain or in poor conditions
• Always maintain adequate distance between the
vehicles, and 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 load or towing ca-
pacity
On grades, it is possible for vehicles to coast at
greater than normal speeds. To prevent loss of vehi-
cle control and possible serious injury, speeds should
be limited to no more than maximum speed on level
ground.
Good common sense and prudent driving practic-
es do more to prevent accidents and injuries than all
of the warnings and instructions combined. Wesley
International strongly suggests that the owner-oper-
ator read this entire manual paying particular atten-
tion to the CAUTIONS, SAFETY INFORMATION, and
WARNINGS.
Wesley International LLC reserves the right to make
design changes without obligation to make these
changes on units previously sold, and the informa-
tion contained in this manual is subject to change
without notice.
Loading and Unloading
Follow these guidelines when loading and unload-
ing cargo:
• Turn the vehicle o while loading or unloading
• Do not exceed the maximum cargo capacity

4
• Carefully and evenly position all loads
• Secure cargo so that nothing can easily fall o of
the vehicle
• Be extremely careful when carrying loads that
extend beyond the vehicle’s deck
Towing
Follow these guidelines when towing:
• Turn the vehicle o and place directional selector
in the center (neutral) position before attaching
load to hitch.
• Ensure hitch is properly installed and secured
(If the vehicle does not have a factory-installed
hitch, the hitch is available from Wesley Interna-
tional.)
• Do not exceed the maximum towing capacity
(The model’s towing capacity is on the Vehicle
Identification plate (Figure 2) and in Appendix C
of this manual.)
• Do not exceed 5 mph when towing
• Take extreme care when towing down an in-
cline
• Avoid sudden stops since the stop may cause the
trailer to jackknife
• Keep in mind that heavy loads being towed may
significantly increase stopping distances
Maintenance
Always maintain your vehicle in accordance with
the service schedule in this manual and keep com-
plete records of the maintenance history of the vehi-
cle. Ensure that maintenance personnel performing
any service or repair work on the vehicle are properly
trained and qualified. When performing any mainte-
nance on the vehicle, disable the vehicle by removing
the key from the key switch and disconnecting the
battery cable.
Untrained or unauthorized personnel should nev-
er attempt to perform service or maintenance on
the vehicle. Improper maintenance can cause haz-
ardous conditions. Contact Wesley International
for authorized service assistance.
Be sure to check the polarity of each battery terminal
and rewire the batteries according to the schematic
shown in this manual (p. 11, Figure 14). 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 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 charging.
Always use insulated tools when working in the
battery area. Improper tools may cause sparks or an
explosion. Wear approved safety goggles or face
shield.
The electrolyte in a lead acid battery is an acid
solution which can cause severe burns to the body
and eyes. Treat all spills to the body and eyes with
extended flushing with clear water; then contact a
physician immediately.
Electrolyte spills will corrode the vehicle’s frame
and body if not treated immediately. Wear prop-
er protective clothing, gloves and eye wear. Thor-
oughly clean all areas with a neutralizing solution
of ¼-cup (60 mL) sodium bicarbonate (baking soda)
dissolved in 1½ gallons (6 L) of water.
Always support the vehicle using wheel chocks and
safety stands. Never get under a vehicle that is sup-
ported by a jack. Lift the vehicle in accordance with
the instructions in this manual (p. 12).
Always test drive the vehicle after any repairs or
maintenance in a safe area free of any other vehicles
or pedestrians.
Wesley recommends that only OEM replacement
parts be used. Using any parts other than those ap-
proved by Wesley may void the warranty.
Ventilation
When performing any maintenance on the Pack
Mule PC NXG or PCT NXG or charging the batter-
ies, make sure that you are in a well-ventilated area.
Hydrogen gas is generated in the charging cycle and
is explosive in concentrations as low as 4%. Five air
exchanges per hour is considered the minimum ven-
tilation required.
The battery charging cycle may generate high-
ly explosive hydrogen gas. Make certain that the
charging is done in a well ventilated area and is
away from anything that might create sparks.
1

5
Operating Instructions
Before Putting Your Vehicle in Service
• Check for leaking fluids (brake fluid, battery acid,
or transaxle oil).
• Check condition of tires for defects or damage.
If your vehicle is equipped with pneumatic tires,
make certain that they are properly inflated.
• Check to ensure that wheel lugs are tight.
• Check to ensure that battery cables are tight and
batteries are secure.
• Check the steering, brake, and electrical controls
for proper operation.
• Charge the batteries.
Vehicle Identification
Figure 2: The Vehicle Identification Plate is located on the
inside of the motor compartment. Please refer to this in-
formation when requesting warranty service, ordering re-
placement parts, or requesting service support from Wes-
ley International.
Charging Batteries
The Onboard High Frequency Charger is standard
on the Pack Mule NXG. To charge the vehicle’s bat-
teries, do the following:
• Position the vehicle in a well ventilated area with-
in six feet of the charging outlet.
• Connect the vehicle’s AC cord (Figure 3) to the
outlet.
• Confirm the charging status on the LED 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 cord for
charging the batteries. Sim-
ply extend the cord and
plug it in to an appropriate
receptacle.
Figure 4: The LED display
on top of the charger in-
dicates when the battery is
completely charged. For a
complete list of LED mes-
sages, see page 17.
Vehicle Controls, Meters, Switches
All of the controls are located on the panel in front
of the operator. They are:
• The On/O switch. The rocker switch (shown
below) is standard, but your vehicle may be
equipped with a key switch, a Safe-T-Lock key-
pad or Perma-Key switch. The Perma-Key switch
is similar to the standard key switch except that
once the key is inserted, it cannot be removed.
• The FWD/NEUTRAL/REV directional selector
switch.
• The Smart View Display (See page 6 for display
information.)
Figure 5: The instrument panel showing (1) the on/o
switch, (2) the directional selector switch, and (3) the
Smart View display.
1
1
2
3

6
Presence Switch
The standard seat presence switch ensures that the
operator is properly positioned in before the vehicle
is put into motion. The vehicle may also be equipped
with a left-foot presence switch. To move the vehi-
cle either forward or backward, the operator must
depress the switch. When the switch is released, the
vehicle stops.
When clearing a fault, make sure that you do not
have the left-foot presence switch engaged. The
fault will not clear when the switch is engaged.
Optional Equipment
Your Pack Mule NXG may be equipped with any of
the following optional equipment:
Headlights/Tail Lights: These are controlled by a
rocker switch located near the directional control.
Parking Brake: The vehicle may have an electronic
or hand parking brake instead of the parking brake
pedal. The electronic brake is automatically engaged
when the motor stops.
Programmable Security Switch: Your vehicle may
be equipped with the optional “SAFE-T-LOCK. The
programmable switch prevents the unauthorized use
of the vehicle and allows up to 99 authorized users.
Instructions for programming the switch are found in
Appendix B.
Tow Hitch: A manufacturer-approved tow hitch is
required for towing a trailer. If the vehicle does not
have the optional factory-installed tow hitch, hitches
matching the vehicle’s tow ability are available from
Pack Mule.
Horn
The horn, located on the floor at the operator’s left
foot 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 “o” 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 is inhibited when
the brake pedal is depressed. The speed increases as
the pedal is depressed, up to the limits set in the con-
troller.
Figure 7: The Accelerator/Brake Pedal. With the key switch
turned to “On”, and the directional switch at “Forward” or
“Reverse, the pedal puts the vehicle in motion. When the
pedal is released, the vehicle stops. .
The FWD/REV directional selector switch is a
three-position rocker switch. Press the top section
down for Forward and the bottom for Reverse. When
neither the top nor bottom position is selected, the
vehicle is in neutral. Always place the directional
switch in neutral when the vehicle is parked or sta-
tionary or when leaving the vehicle.
The static return-to-o feature prevents the vehi-
cle from starting with a direction selected. To start
the vehicle, put the switch in the neutral position
and turn the key on.
The Smart View Display
The Smart View display communicates directly with
the onboard controller and displays important vehi-
cle information when the key is switched on:
• Battery State of Charge (Displayed as a percent-
age of charge remaining.)
• Traction Hours (the time the switch is on)
• System Fault Code (See page 17 for an explana-
tion of the fault codes.)

7
Figure 8: The optional parking brake in the OFF position.
Parking brake tension may be adjusted by turning the knob
at the end of the handle (indicated by the arrow)..
The Back-up or Proximity Alarm: The back-up
alarm sounds continuously when the direction se-
lector switch is set to reverse. The proximity alarm
sounds continuously when the direction selector
switch is set to either forward or reverse.
7. Engage the left-foot presence switch (if present)
with the left foot.
8. Gradually press the accelerator pedal. The speed
of the vehicle, up to the limit set by the control-
ler, is determined by the amount of pedal trav-
el.
9. To stop, remove your foot from the accelerator/
brake pedal.
Driving the Pack Mule NXG
The Pack Mule vehicle is designed to be simple to
use. However, for safe operation, the operator must
practice appropriate operating techniques, as out-
lined below. This list assumes that the daily mainte-
nance schedule (p. 8) has been followed.
1. Make certain that the battery charger AC cord
is unplugged and properly stored. The vehicle
control is interlocked so that the vehicle will not
move when the on-board charger is plugged
in.
2. Check the surrounding area to make sure that it
is clear of obstruction and make certain that the
cargo is properly loaded and secured.
3. Make 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 O/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 direc-
tion. If the accelarator is depressed while the
directional switch is set to “Neutral,” the Smart
View Display will show a fault. To clear the fault,
turn the O/On switch to O, then back on. Set
the directional switch to desired direction.
Parking
• Set the directional switch to the neutral posi-
tion.
• Set the key switch or rocker switch to “O.”
• Apply the parking brake and depress the brake
pedal as needed.
• If parking on an incline, turn the front wheels into
the curb to prevent accidental movement.
Figure 9: Proper positioning of the Pack Mule’s front
wheels when parking on an incline.
Driver Assist on Inclines
Unlike other electric utility vehicles, the Pack Mule
NXG has a controller that seamlessly applies the re-
generative brakes to limit speeds on descending in-
clines and provides additional power as needed on
ascending inclines.
Although the Pack Mule NXG provides automatic re-
generative braking on inclines, operators should be alert
to vehicle and load instability on unlevel surfaces.
Excessive brake tension will cause cable wear and
may cause brake failure.
Uphill

8
Start-up Checklist
Below is a sample checklist of tasks to be performed each day before the vehicle is put into service. It covers
the daily maintenance in the maintenance list found on the next page.
Truck No. ___________________________________ Operator ____________________________ Date __________
Visual OK Fix
Obvious Damage
Cracked Frame Welds
Model Tag Readable
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) position when leaving the ve-
hicle.
After completing the inspection, the operator should turn the form in to the supervisor, who should keep the
form on file for thirty days.

9
Service Monthly
Bi-
Annual Annual
1. Check operation of all gauges, horn, and
lights. P P P
2. Check BDI for battery state of charge. P P P
3. Charge batteries when vehicle is not in ser-
vice. Charge overnight up to 8 hours. P P P
4. Check tires for cuts, excessive wear, and
cold pressure. P P P
5. Check wheels for bent rims, missing or
loose lug nuts. P P P
6. Check battery for correct electrolyte lev-
el. P P P
7. Check for loose steering. Adjust as re-
quired. P P P
8. Clean batteries and terminals with a solu-
tion of ¼ cup (60 mL) baking soda to 1½
gallon of water. Tighten terminals and coat
with anti-corrosion compound.
P P P
9. Inspect brake system linkages, brake lin-
ings and other components for wear and
adjustment. P P
10.Check specific gravity of all battery cells
using hydrometer. P P
Notes:
1. In freezing temperatures recharge the batteries after adding distilled water to make sure that 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 aect vehicle handling. It may also lead to sudden tire failure, resulting
in a loss of vehicle control.
3. A hydrometer, measuring the specific gravity of the electrolyte, is used to determine if a battery is properly
charged. With a fully charged battery, the reading should be about 1.260; fully discharged it should be about
1.100.
4. The transaxle is sealed and does not require routine maintenance.
Maintenance Schedule
The Pack Mule NXG vehicle is virtually maintenance free in its standard configuration. It has a sealed
AC motor with no brushes to be replaced, and the transaxle is sealed and does not require periodic
lubrication. The list belows what should be done monthly, Bi-Annually (or at 125 hours of operation)
, and Annually (or at 250 hours of operation). Operating hours are shown on the display on the in-
strument panel.

10
Maintenance Instructions
Routine Maintenance
Before performing any maintenance or repair work
on the vehicle, isolate the batteries from the motor
and electronics by removing the 10-amp fuse. (Figure
10) When finished, replace the fuse .
Figure 11: The major components
of the electrical system. They are
(1) motor, (2) controller, (3) coil
(with fuse) and (4) batteries.
Batteries
The standard batteries used in the Pack Mule are
lead acid, 6-volt, deep cycle, golf-cart style. Other
battery types are available.
Always observe the following warnings when
working on or near batteries:
Keep all smoking materials, open flames, or sparks
away from batteries. Any flame or spark might cause
an explosion.
Do not charge 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
“O” position, all electrical accessories are o, 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 the skin and
eyes. If you come into contact with the electrolyte,
flush the area with plenty of clear water and contact
a physician immediately.
Always use properly insulated tools when working
on electric vehicles. Properly insulated tools will
help to prevent electrical shock that can result in
equipment damage, severe personal injury or even
death.
Figure 10: The fuse (indicated by the arrow) should be re-
moved before performing any maintenance or repair work
on the electrical system.
1
2
3

11
Battery Care
The useful life of the batteries installed in the Pack
Mule NXG vehicle will be longer if they are properly
cared for. Keep the following in mind:
• Place battery into service and complete a full
discharge and charge cycle. Check the electro-
lyte level, and add approved water (never acid) if
needed after this first cycle is completed.
• Never discharge the battery beyond 80%, and do
not use the battery if the specific gravity falls be-
low 1.150.
• During shipment or prolonged storage, the elec-
trolyte levels may fall below the separator pro-
tector. Keep electrolyte levels above the separa-
tor and /” (3.175mm) below the vent well. Water
batteries only as required and after a complete
charge and discharge cycle.
• Use only distilled or purified water, free of con-
taminants. (Contaminants in water may reduce
the chemical reaction causing a reduction in bat-
tery life.)
• Be sure to replace the vent caps after watering to
prevent electrolyte from spilling out.
• Keep the battery top clean and dry, and the vent
caps tightly sealed.
• Keep open flame and metal objects away from
the battery top.
• Keep the battery compartment open and well
ventilated during the charging cycle.
• Charge batteries after each day’s use.
Electrolyte Levels
The electrolyte levels should be carefully monitored
and maintained ½” (13mm) above the plates in each
cell. If the electrolyte level is too low, the plates will
be exposed to air and ruined beyond repair. If it is too
high, the electrolyte will be forced out of the battery
during the charge cycle.
Optional Battery Watering System
Pack Mule oers battery watering systems as an op-
tion for the Pack Mule NXG. This system provides a
fast, accurate, and safe way to maintain precise bat-
tery electrolyte levels.
Cleaning Batteries
For ecient 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 ¼ cup (60 mL) of sodium bicarbonate with 1½
gallons (6 L) of water. Apply the solution to the top
and sides of the batteries and allow the solution to
sit for three minutes. Thoroughly rinse the area with
low-pressure, clear water.
Battery Replacement
Care should be taken in removing and replacing
batteries. Each battery weighs approximately 70
pounds. Lifting the battery without using appropri-
ate equipment may cause injury.
To remove the battery, remove the 10-amp fuse
(Figure 10), remove the hold-down clamps and inter-
connected cables. Ensure that the battery fill caps are
securely attached. Then attach the lifting device and
remove the battery.
Connecting the Batteries
All configurations (24 v, 36 v and 48 v) of the Pack
Mule batteries are connected in series as shown in
Figure 12. The red wire is connected to the battery
positive input connection, the remainder of the bat-
teries are connected negative to positive, and the
black wire is attached to the last battery’s negative
connection. According to the voltage, your vehicle
may have eight batteries instead of six; however, the
series connection is the same.
Figure 12: The batteries connected in series.
Always wear proper safety equipment, includ-
ing safety goggles or a face shield when working
around batteries.
To protect against personal injury or equipment
damage, always use insulated tools when working
on an electric vehicle
Vehicles with on-board chargers have a tempera-
ture sensor attached to the negative terminal to pre-
vent overheating during recharge.

12
Lifting the Vehicle
Lifting the front: To remove a front wheel or axle:
First chock the front and rear of the rear tires. Loos-
en the front wheel hardware. Position the jack in the
location indicated in Figure 13 below and carefully
raise the front of the vehicle, taking care that the rear
wheels do not move. Position jack stands in the lo-
cations indicated and slowly lower the vehicle to rest
on the jack stands and test the stability of the vehicle.
Lifting the rear: To remove a rear wheel or axle, first
raise the front of the vehicle as previously described
and support on jack stands. Then position the jack
in the position indicated at the rear of the vehicle.
Carefully raise the rear of the vehicle with the jack
and place two jack stands in the positions indicated.
Slowly lower the vehicle to rest on the jack stands
and test the stability of the vehicle. Lower the vehicle
by reversing the lifting sequence.
The vehicle may be lifted with an overhead crane
and J-Hooks. The J-hooks should be attached to the
frame at the four corners of the battery/engine com-
partment. The crane capacity should be greater than
1200 lbs (standard battery) or 1500 lbs (industrial bat-
tery). Do not work under the machine when hoisted
by a crane.
Figure 13: Position the jacks or jack stands
Do not lift the 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 (o-white)
Although all of these should be inspected periodi-
cally, only the pneumatic tires require maintenance.
Make certain that the tire pressure is maintained at 60
psi for LRB tires and 90 psi for LRC tires.
Changing the vehicle’s tires is very much like chang-
ing an automobile tire. Follow the procedure below
to change the tire safely.
1. Position the jack in the proper position (Figure
13)
2. Loosen the lug nuts on the wheel to be changed.
3. Raise the jack until the tire is clear of the sur-
face.
4. Remove the tire.
To replace the tire, reverse the procedure, tighten-
ing the lug nuts to 70 to 80 ft. lbs. (95 to 108 Nm)
torque.
Brakes
The vehicle is equipped with a pair of rear mechan-
ical drum brakes which only engage for parking and/
or emergency stopping. Normal braking uses the
regenerative braking controlled by the combination
accelerator/brake pedal.
Mechanical brakes are adjusted by advancing the
two nuts on the central rod until the slop disappears.
Brake wear may cause the need for a repeat adjust-
ment..
Tires and Wheels
Your Pack Mule vehicle may be equipped with any
one of the following types of tires:
• Pneumatic (standard)
• Solid
Figure 14: To adjust the mechanical drum brakes, advance
the two nuts on the central rod (indicated by the arrow)..
12

13
Electrical Components
Onboard Battery Charger
Your Pack Mule NXG is equipped with an onboard
Delta-Q Battery Charger. The charger is air-cooled
with no moving parts, providing dependable charging
with little maintenance. To assure continued trou-
ble-free operation, you should be aware of the fol-
lowing:
• The cooling fins on the charger should be
checked regularly, making sure that they are free
of dirt, dust, and other contaminants.
• The charger is designed to operate in environ-
ments between -30°C (-22°F) to 50°C (122°F).
• Do not expose the charger to oil, mud, or heavy
water spray when cleaning the vehicle.
Flashes Cause Solution
1 Battery high voltage Check battery size and condition. This fault will clear automatically
once the condition has been corrected.
2 Battery low voltage Check battery size and condition. This fault will clear automatically
once the condition has been corrected.
3Charge timeout caused by the
batter pack not reaching the
required voltage or charge
Check connections, that battery type matches the selected charge
profile and operate the charger at a lower ambient temperature. Reset
the charger by interrupting the AC for at least 15 seconds.
4Battery 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 sucient 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
fault persists, it is likely the charger will need to be replaced.
Ammeter
• If solid: displays scale of output
during bulk phase.
• If flashing: Output has been re-
duced due to high internal char-
ger temperature. Displays charge
profiles 1-6 for 11 seconds if no
battery is present.
Fault Indicator (Red Light)
• Charger error. Count the number
of flashes between pauses and
refer to the troubleshooting infor-
mation in the table below.
Bulk Charge Indicator
• If solid: Bulk charge phase complete (80%
charge); in absorption phase.
• If flashing: Displays charge profile num-
ber if no battery is connected.
Charge Completion Indicator (Green Light)
• If solid: Charging complete and mainte-
nance mode is active.
• If flashing: Absorption phase complete, in
finishing phase.
AC Indicator
• If solid: AC power is present.
• If flashing: Low AC voltage. Check electri-
cal source and cord length.
Troubleshooting Instructions
If a fault occurs, count the number of flashes between pauses and refer to the table below.

14
Onboard Battery Charger (continued)
If the detachable input power supply cord set
is damaged, replace with a cord that is: (for North
America) UL or CSA listed/approved detachable cord,
3 conductor, 16AWG minimum, and rated SJT; termi-
nating in a grounding type IEC 60320 C14 plug rat-
ed 250V, 13A minimum; or (for all other countries)
a safety approved detachable cord, 3 conductor,
1.5mm² minimum, rated appropriately for industrial
use. The cord set must be terminated on one end
with a grounding type input connector appropriate
for use in the country of destination and, on the other
end, an output grounding type IEC 60320 C14 plug.
Extension cords must be 3-wire cord no longer than
30m (100’) at 10AWG or 7.5m (25’) at 16AWG per UL
guidelines.
Connect only one charger to a single 15A circuit or
the circuit may become overloaded.
Charger enclosure may be hot during charging.
Use hand protection if handling the charger while
charging.
To prevent risk of 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 supply before making or breaking the con-
nections to the battery.
Do not open or disassemble charger. Do not op-
erate this charger if the AC supply cord is damaged
or if the charger has received a sharp blow, been
dropped, or otherwise damaged in any way. Refer
all repair work to the manufacturer or qualified per-
sonnel.
This appliance is not intended for use by persons
(including children) with reduced physical, senso-
ry or mental capabilities, or lack of experience and
knowledge, unless they have been given supervi-
sion or instruction concerning use of the appliance
by a person responsible for their safety.
If the optional single-LED display is included, it will be located on the front panel, near the key switch.
Optional Single LED Display