American Landmaster 36V 200 Series Service Manual Download Page 2

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200 Series 36V

15312

Section 1 -

General Information ............................................ 1

Model Identification.................................................................... 1

Frame Number ................................................................... 1

Specifications ............................................................................. 1

Section 2 -

Maintenance ......................................................... 2

Periodic Checks and Services ...................................................... 2

Maintenance and Tune-Up Procedures ........................................ 2

Tire Pressure / Wear ........................................................... 2

Brake Fluid and Performance ............................................... 3

Chassis Nuts and Bolts ........................................................ 3

Chassis Lubrication ............................................................. 3

Belt Tension ....................................................................... 4

Motor ................................................................................. 4

Batteries ............................................................................ 4

Section 3 -

Motor and Controller ............................................ 4

Motor removal and Installation ................................................... 4

Motor Removal ................................................................... 4

Motor Installation ............................................................... 5

Controller Removal and Installation ............................................. 5

Controller Removal ............................................................. 5

Controller Installation .......................................................... 5

Section 4 -

Drive System ........................................................ 5

Belt Tensioning and Replacement ............................................... 5

Belt Tensioning ................................................................... 5

Primary Belt Replacement ................................................... 6

Secondary Belt Replacement ............................................... 6

Section 5 -

Throttle ................................................................ 7

Throttle Installation and Adjustment ........................................... 7

Throttle Assembly Removal ................................................. 7

Throttle Sensor Removal ..................................................... 7

Throttle Safety Switch Removal ........................................... 7

Throttle Safety Switch Installation ........................................ 7

Table of Contents

Summary of Contents for 36V 200 Series

Page 1: ...15312 Service Manual 200 Series 36V...

Page 2: ...es 4 Section 3 Motor and Controller 4 Motor removal and Installation 4 Motor Removal 4 Motor Installation 5 Controller Removal and Installation 5 Controller Removal 5 Controller Installation 5 Section...

Page 3: ...Troubleshooting 16 Flowchart 16 Procedures 17 Throttle Harness Throttle Sensor Potentiometer Signal 17 Throttle Harness Throttle Switch Signal 17 Throttle Position Sensor Potentiometer 18 Throttle Swi...

Page 4: ...h Track Width Front Rear 1160mm 47 7inch 1000mm 39 4inch Ground Clearance 170mm 6 7inch PERFORMANCE Motor Type 36V 300A Electric SepEx Output Power Torque 9 9 hp 7500rpm 13ft lbs 5500rpm Starting Keye...

Page 5: ...ty or muddy areas require more frequent servicing Interval Initial service first week Monthly Quarterly Yearly Tire Pressure Wear p 2 I I Brake Fluid and Performance p 3 I I Chassis Nuts and Bolts p 3...

Page 6: ...Ib ft N m Kg m Ib ft 4 1 2 0 1 0 2 0 7 1 5 1 5 3 0 15 0 3 1 0 2 0 5 1 4 0 2 0 4 1 5 3 0 3 6 0 3 0 6 2 0 4 5 6 4 7 0 4 0 7 3 0 5 0 8 12 0 8 1 2 6 0 8 5 8 10 16 1 0 1 6 7 0 11 5 18 28 1 8 2 8 13 0 20 0...

Page 7: ...nting bolt tension and condition of insulating washers Clean motor with soapy water to allow proper cooling Batteries Clean surfaces of batteries with a solution of water and baking soda Inspect for d...

Page 8: ...ttaching it to the mounting plate then remove the upper bolts Notice the order of washers as the bolts are removed 5 Carefully pull the motor away from the mounting plate allowing the drive pulley to...

Page 9: ...4 Tighten the smaller 3 8 tensioner bolt to lock the tensioner in place It is not necessary to tighten the center nut on the tensioner but it may be tightened if desired or if tensioner slip is occur...

Page 10: ...ndary drive belt by sliding it off of its pulley down the axle shaft to the left through the slot of the swingarm axle bracket and then off the axle 9 Install the new belt by sliding it over the axle...

Page 11: ...cket Outward force may be applied to the clip to align with the holes 11 Carefully apply even pressure on the clip to insert it into the holes The sensor can get damaged if care is not taken here The...

Page 12: ...Page 9 200 Series 36V 15312 Section 6 ELECTRICAL SYSTEM SCHEMATICS Figure 1 Vehicle Schematic...

Page 13: ...15312 200 Series 36V Figure 2 Motor Controller Schematic...

Page 14: ...te level the minimum level is at the top of the plates 3 If necessary add just enough water to cover the plates at this time and replace the vent caps 4 Put batteries on a complete charge before addin...

Page 15: ...ts located underneath the battery rack 6 Remove battery hold down 7 Slide end battery out and remove from system NOTE the orientation of the battery as it is removed Repeat for all others to be replac...

Page 16: ...d to jump the battery so charging can begin With the charger plugged in connect another external source such as a 12V dumb charger or a separate 12V battery to the terminals of the low voltage battery...

Page 17: ...a voltage that is not relevant As batteries sit unused the voltage may creep up but the useable potential of the batteries is not there If the discharge meter is not resetting to full the charger shou...

Page 18: ...Page 15 200 Series 36V 15312 Section 8 BRAKES BRAKE SYSTEM REPLACEMENT...

Page 19: ...Check for 12V at Key Switch Red and Black on harness side Relay clicks once Check connections at Relay Ensure 12V at Black wire when key ON 36V at Orange Contactor wires Touch Pre charge Resistor If h...

Page 20: ...ires in it Use setting on the meter Place one probe on the end of the gray wire and one on the end of the gray wire with the black stripe With plunger extended throttle returned the resistance should...

Page 21: ...d the throttle switch is also good and does not need tested as an individual component Throttle Position Sensor Potentiometer Use setting on the meter Unplug the throttle position sensor from the harn...

Page 22: ...one probe on each spade terminal on the Switch With the button pushed in throttle fully returned the meter should say OL With the button extended throttle pressed there should be a value shown close t...

Page 23: ...or the models with gas engines o Chassis harness yellow plug inserted fully o Relay plug Blue or Black automotive relay o The dash panel harness especially the bullet connectors make sure they are tig...

Page 24: ...ery It should read greater than 12 volts on each battery Battery Checks Battery System Use V setting on the meter Place one probe on the negative post at the 350 amp fuse Place the other on the positi...

Page 25: ...and one probe to a good chassis ground such as the negative post at the 350 amp fuse Turn the ignition key to the ON position The meter should read 12 14 volts Controller Power from 36V Harness Use V...

Page 26: ...t present check all connections and splices in the 36 volt harness and repair as necessary Wiring must be traced to locate the item that is disrupting the circuit Relay Make sure it makes a faint clic...

Page 27: ...a blown fuse If still no power check all connections pins wires locations same as you would for the models with gas engines o Relay plug Blue or Black automotive relay o ALL pins at ALL connectors of...

Page 28: ...e BLACK probe to a good chassis ground such as the negative post at the 350 amp fuse Turn the ignition key to the ON position The meter should read at least 36 volts Meter Result 36V One probe placeme...

Page 29: ...Place the other at the controller s B position on the cable coming from the contactor It should read approximately 30 volts Action If the required voltage is not present wiring must be traced to locat...

Page 30: ...d one on the other post The reading should be approximately 680 ohms If this does not happen replace the resistor Note Additionally a hot resistor across the Contactor indicates a failed controller Co...

Page 31: ...15312 200 Series 36V Measuring from F to F will be around 9M Measuring from M to B will be around 18 25K From M to B will start around 18 25K and charge up as the meter is connected...

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American Landmaster 36V 200 Series, Service Manual

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