Cushman MINUTE MISER Technician'S Repair And Service Manual Download Page 36 | Manualshive

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TABLE OF CONTENTS FOR SECTION ‘C’

SECTION TITLE

PAGE NO.

Page C-i

Repair and Service Manual

C

BODY

BODY .............................................................................................................................................. C - 1

General................................................................................................................................. C - 1

BODY COMPONENT REPLACEMENT.......................................................................................... C - 1

LIST OF ILLUSTRATIONS

Fig. 1 Drill Out Metal Rivet ............................................................................................................. C - 1
Fig. 2 Body Components................................................................................................................ C - 2

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Summary of Contents for MINUTE MISER

Page 1: ...ELECTRIC POWERED THREE WHEEL SERVICE VEHICLE ISSUED NOVEMBER 2003 REVISED FEBRUARY 2007 TECHNICIAN S REPAIR AND SERVICE MANUAL 600198 G01...

Page 2: ...arification Always replace any damaged or missing labels On steep hills it is possible for vehicles to coast at greater than normal speeds encountered on a flat surface To pre vent loss of vehicle con...

Page 3: ...nd the informa tion contained in this manual is subject to change without notice E Z GO Division of Textron Inc is not liable for errors in this manual or for incidental or consequential damages that...

Page 4: ...discharge varies depending on the ambient temperature and the age and condition of the batteries A fully charged battery will not freeze in winter temperatures unless the temperature falls below 75 F...

Page 5: ...discharge varies depending on the ambient temperature and the age and condition of the batteries A fully charged battery will not freeze in winter temperatures unless the temperature falls below 75 F...

Page 6: ...nformation v TITLE SECTION General Information Routine Maintenance A Safety B Body C Wheels and Tires D Batteries Charging E Electronic Speed Control F Motor G Electrical System Battery and Charger H...

Page 7: ...Page iv Repair and Service Manual TABLE OF CONTENTS Notes...

Page 8: ...use of the material in this manual This vehicle conforms to the current applicable standard for safety and performance requirements These vehicles are designed and manufactured for off road use They...

Page 9: ...ectly Always use specified replacement parts Never use replacement parts of lesser quality Always use recommended tools Always determine that tools and procedures not specifically recommended by the m...

Page 10: ...exchanges per hour is considered the minimum requirement Never charge a vehicle in an area that is subject to flame or spark Pay particular attention to natural gas or propane gas water heaters and fu...

Page 11: ...Owner s Manual and Service Guide SAFETY INFORMATION Page viii Notes...

Page 12: ...A 6 Accelerator Pedal A 6 Horn and Handlebar A 6 Handlebar Installation A 7 Seat Switch A 7 Hour Meter Accessory A 7 ADDITIONAL FEATURES A 7 Battery Charger A 7 Fold Down Backrest A 7 Programmable Sp...

Page 13: ...Service Manual A GENERAL INFORMATION ROUTINE MAINTENANCE Fig 13 Direction Selector Switch A 6 Fig 14 Speed Control Pedal A 6 Fig 15 Seat Switch A 7 Fig 16 Battery Charger A 7 Fig 17 Fold Down Backrest...

Page 14: ...n working around batteries or using solvents or compressed air To reduce the possibility of causing an electrical arc which could result in a battery explosion turn off all electrical loads from the b...

Page 15: ...amage components Putting more than three pumps of grease in a grease fit ting could damage grease seals and cause premature bearing failure REAR AXLE The only maintenance to the rear axle for the firs...

Page 16: ...rews previously removed To replace the taillight bulb roll the rubber bezel from around the edge of the taillight and remove lens Replace with new bulb Replacement headlight and taillight bulbs and 15...

Page 17: ...emperature ranges P N 75502 G01 Penetrant Lubricant a 4 in 1 product that pene trates the most stubborn of frozen parts lubricates leaving a light lubricating film prevents corrosion by adhering to we...

Page 18: ...ndlebar 1 Handlebar 2 Horn Key Switch The key switch located in the vehicle dash supplies or interrupts power to the vehicle electrical system ON POSITION Supplies power OFF POSITION Interrupts power...

Page 19: ...on the floorboard Depressing the pedal will slow or stop the vehicle Once the vehicle has stopped the parking brake can be engaged by pressing the front por tion of the pedal The floorboard catch shou...

Page 20: ...vement NEV ER operate the vehicle if the seat switch is malfunctioning Hour Meter Accessory The hour meter located in the motor compartment behind the speed controller records the number of hours the...

Page 21: ...vehicle or the lack of proper maintenance may result in decreased performance or damage to the vehicle Read and understand the following warnings before attempting to operate the vehicle To reduce th...

Page 22: ...rmal speeds that may be encountered on a flat surface To prevent loss of vehicle control speeds should be limited to no more than the maximum speed on level ground see GENERAL SPECIFICATIONS Limit spe...

Page 23: ...es items listed in previous table the following BATTERIES Clean batteries terminals with 1 4 cup 60 ml baking soda to 1 1 2 gallons 6 liters water solution rinse with clear water Check charge conditio...

Page 24: ...chnician s Repair and Service Manual Check brake shoe linings see Technician s Repair and Service Manual BODY Clean body components and wax all painted surfaces STEERING Lubricate use wheel bearing gr...

Page 25: ...L INFORMATION ROUTINE MAINTENANCE Page A 12 Repair and Service Manual Read all of Section B and this section before attempting any procedure Pay particular attention to all Notes Cautions and Warnings...

Page 26: ...CAUTIONS AND WARNINGS B 5 IMPORTANT SAFETY WARNING B 5 MODIFICATIONS TO VEHICLE B 5 GENERAL MAINTENANCE B 5 BEFORE SERVICING THE VEHICLE B 6 Additional Warnings B 6 LIFTING THE VEHICLE B 7 Towing B 7...

Page 27: ...SAFETY Page B ii Repair and Service Manual Notes...

Page 28: ...ts capacity or safe operation or make any change not in accordance with the owner s manual without the manufacturer s prior written authori zation Where authorized modifications have been made the use...

Page 29: ...erience 5 2 3 The user should include in the operators train ing program the following a instructional material provided by the manufac turer b emphasis on safety of passengers material loads carrier...

Page 30: ...It is advisable that all other personnel leave the elevator before a carrier is allowed to enter or exit 5 5 13 Avoid running over loose objects potholes and bumps 5 5 14 To negotiate turns reduce spe...

Page 31: ...cleaning parts j Properly ventilate the work area k Handle LP gas cylinders with care Physical dam age such as dents scrapes or gouges may danger ously weaken the tank and make it unsafe for use l Bra...

Page 32: ...around you if the compo nent should move unexpectedly Some components are heavy spring loaded highly cor rosive explosive or may produce high amperage or reach high temperatures Battery acid and hydro...

Page 33: ...ult in severe injury or death keep all smoking materials open flame or sparks away from the batteries Hydrogen gas is generated in the charging cycle of batteries and is explosive in concentrations as...

Page 34: ...a chain hoist attached to the front frame members Always use an additional safety chain to pre vent injury should the hoist malfunction To remove the front axle loosen the hardware and turn the front...

Page 35: ...Inc 1430 Broadway New York New York 10018 USA OR Underwriters Laboratories Inc 333 Pfingsten Road Northbrook Illinois 60062 USA This Electric Vehicle complies with ANSI B56 8 as it applies to OSHA fo...

Page 36: ...NTS FOR SECTION C SECTION TITLE PAGE NO Page C i Repair and Service Manual C BODY BODY C 1 General C 1 BODY COMPONENT REPLACEMENT C 1 LIST OF ILLUSTRATIONS Fig 1 Drill Out Metal Rivet C 1 Fig 2 Body C...

Page 37: ...BODY Page C ii Repair and Service Manual Notes...

Page 38: ...th pop rivets which require that the rivet head be removed in order to push out the shank of the rivet The rivet head is easily removed by drilling into the head with a sharp drill bit that is slightl...

Page 39: ...BODY Page C 2 Repair and Service Manual Read all of Section B and this section before attempting any procedure Pay particular attention to all Notes Cautions and Warnings Fig 2 Body Components...

Page 40: ...and Service Manual D WHEELS AND TIRES WHEEL AND TIRE SERVICE D 1 Tire Repair D 1 Wheel Installation D 1 Removing and Reinstalling Front Tire D 2 Removing and Reinstalling Rear Tire D 2 LIST OF ILLUSTR...

Page 41: ...WHEELS AND TIRES Page D ii Repair and Service Manual Notes...

Page 42: ...he same pressure for optimum han dling characteristics Be careful not to overinflate Due to the low volume of these small tires overinflation can occur in a matter of seconds Be sure to install the va...

Page 43: ...ock 2 Axle Nut 3 Retaining Washer 4 Wheel Retaining Nut 5 Valve Stem 1 Loosen the axle nuts and lower entire wheel hub and axle assembly from front fork Remove the four wheel retaining nuts 2 Complete...

Page 44: ...aning Batteries E 3 Battery Replacement E 3 Prolonged Storage E 4 Battery Charging E 5 AC Voltage E 5 TROUBLESHOOTING E 5 Hydrometer E 5 Using A Hydrometer E 6 LIST OF ILLUSTRATIONS Fig 1 Correct Elec...

Page 45: ...BATTERIES AND CHARGING Page E ii Repair and Service Manual Notes...

Page 46: ...ling batteries may result in electrolyte being expelled from the battery during the charge cycle Expelled electrolyte may cause personal injury and damage to the vehicle and storage facility Wrap wren...

Page 47: ...e majority of the gassing taking place at the end of the charging cycle This gas is hydrogen which is lighter than air Water and sulfuric acid droplets will be carried out of the battery vents by the...

Page 48: ...mixed with 1 1 2 gallons 6 liters of clear water Ref Fig 4 on page E 3 In addition to the batteries special attention should be paid to metallic components adjacent to the batteries which should also...

Page 49: ...90 F 32 C will lose 002 of specific gravity each day If a fully charged battery has a specific gravity of 1 275 and the battery is allowed to sit unused it will become partially discharged When it rea...

Page 50: ...lt the battery manufacturer or a service representative for specific requirements The second reason is to determine why a particular vehi cle does not perform adequately Performance problems may resul...

Page 51: ...e scale on the float 4 Add or subtract four points 004 to the reading for every 10 F 6 C the electrolyte temperature is above or below 80 F 27 C Adjust the reading to conform with the electrolyte temp...

Page 52: ...indicates a problem with the low reading cell s As a battery ages the specific gravity of the electrolyte will decrease at full charge This is not a reason to replace the battery providing all cells...

Page 53: ...BATTERIES AND CHARGING Page E 8 Owner s Manual and Service Guide Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings Notes...

Page 54: ...EED CONTROL PROGRAMMABLE SPEED CONTROLLER F 1 DIAGNOSTICS AND TROUBLESHOOTING F 1 LED Diagnostics F 1 LIST OF ILLUSTRATIONS Fig 1 Controller LED Status Indicator F 1 Fig 2 Controller LED Status Indica...

Page 55: ...ELECTRONIC SPEED CONTROL Page F ii Repair and Service Manual Notes...

Page 56: ...speed limit adjustment DIAGNOSTICS AND TROUBLESHOOTING LED Diagnostics During normal operation with no faults present the Sta tus LED flashes a single flash at approximately 1 flash second If the cont...

Page 57: ...rottle pot defective 4 Wrong throttle type selected 2 2 BB WIRING CHECK emer reverse wiring fault 1 BB wire open 2 BB check wire open 2 3 HPD HPD sequencing fault 1 Improper seq of KSI brake throttle...

Page 58: ...thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings 4 3 THERMAL CUTBACK over under temp cutback 1 Temperature 85 C or 25 C 2 Excessive load on vehicle 3...

Page 59: ...during ramp start in low speed Acceleration Rate 0 3 1 0 8 Sec Time to reach full output from zero output Quick Start 0 6 1 4 0 2 Output will respond to rate of throttle change Throttle type type 1 2...

Page 60: ...val G 1 Motor Disassembly G 1 Bearing Replacement G 1 Brush Replacement G 2 Motor Assembly G 3 Motor Tests G 3 Motor Installation G 3 LIST OF ILLUSTRATIONS Fig 1 Disconnect Battery Cable G 1 Fig 2 Mar...

Page 61: ...MOTOR Page G ii Repair and Service Manual Notes...

Page 62: ...an insulated wrench disconnect the negative battery cable from the battery Ref Fig 1 on page G 1 Remove all wires from motor Mark both the axle and motor housings to permit realign ment during reassem...

Page 63: ...ll the snap ring If brushes are to be replaced proceed now to Brush Replacement before installing the armature For proper location the armature has a positive stop feature When installing armature int...

Page 64: ...ailure When a test of the power wiring system indicates that the system is operating correctly and the vehicle either does not run or runs poorly the motor is the only remaining component and must be...

Page 65: ...MOTOR Page G 4 Repair and Service Manual Read all of Section B and this section before attempting any procedure Pay particular attention to all Notes Cautions and Warnings Notes...

Page 66: ...t Take A Charge H 6 DC Circuit Continuity Test H 6 Charger DC Fuse Blows H 7 Electronic Timer Testing H 7 Testing The Charger H 8 The Transformer Is Silent H 8 An AC Line Fuse Or Circuit Breaker Blows...

Page 67: ...ELECTRICAL SYSTEM AND BATTERY CHARGER Page H ii Repair and Service Manual Notes...

Page 68: ...s important to determine the condition of the battery set before proceeding with any electrical troubleshooting An open voltage test is of little use since a battery that has deteriorated to the point...

Page 69: ...audible indication when the switch is operated A normally closed NC switch will cause the meter to show 0 or give an audible indication when the probes are attached without activating switch The audi...

Page 70: ...H LOCATION INDICATED USING THE SEQUENCE INDICATED BY REFER TO NOTE SYMBOL FOR SPECIFIC INSTRUCTIONS IF REFERENCE VOLTAGE IS NOT PRESENT CHECK WIRING ASSOCIATED WITH TEST IF WIRING IS SATISFACTORY REPL...

Page 71: ...tes Cautions and Warnings Fig 4 Wiring Diagram Cont BRN BRN WHT BLU WHT GRN WHT BLU WHT BLU WHT RED BLU WHT YEL YEL GRN GRN ORN BLK GRN A2 A1 S2 S1 MOTOR REVERSE SOLENOID FORWARD SOLENOID BLU RED RED...

Page 72: ...2671 A1 S1 A2 S2 ORN YEL BLU GRN ACC IGN BATT KEY SWITCH 886311 RED WHT BLU WHT BLU YEL YEL REVERSE DIRECTION SWITCH 836354 YEL YEL YEL YEL YEL YEL RED RED ORN ORN BRN BRN GRN GRN FORWARD REVERSE WARN...

Page 73: ...er tests If the fuses are good go to next step 3 Use a low voltage test light or Ohmmeter Connect the tester leads to the charger output leads and note the reading 4 Reverse the tester leads and check...

Page 74: ...ode conducts current in both directions the diode is shorted and the entire heat sink assem bly with diodes must be replaced If the above steps fail to reveal the malfunction check the wiring of both...

Page 75: ...at the DC output leads should be zero 4 Unplug the AC supply cord then connect the DC out put leads to the batteries After 2 to 5 seconds you should hear a Click as the relay closes 5 Plug the AC supp...

Page 76: ...Darkening of all the transformer secondary coil windings is an indication of possible over heating damage A low or complete lack of output would be observed on the ammeter however the transformer may...

Page 77: ...or voltage can be as high as 660 volts AC Use extreme care when working near the capacitor termi nals High voltage can cause shocks burns or death Determine whether the transformer secondary coil is w...

Page 78: ...POINTS INSIDE CHARGER BLACK BLACK BLACK POS NEG TO DC PLUG AND BATERIES RED GREEN TRANSFORMER PRIMARY COIL PRIMARY COIL TRANSFORMER COIL VOLTAGE TEST without capacitor TRANSFORMER COIL VOLTAGE TEST wi...

Page 79: ...RICAL SYSTEM AND BATTERY CHARGER Page H 12 Repair and Service Manual Read all of Section B and this section before attempting any procedure Pay particular attention to all Notes Cautions and Warnings...

Page 80: ...k J 2 Automatic Adjuster Mechaninism J 2 HOW THE PAKING BRAKE WORKS J 3 BRAKE DRUM AND SHOE REMOVAL J 3 Brake Drum Removal J 3 Brake Shoe Removal J 4 Brake Removal J 4 Brake Adjustment J 5 Brake Repai...

Page 81: ...Page J ii BRAKES Repair and Service Manual Notes...

Page 82: ...ILY BRAKE PERFORMANCE TEST All brake tests must be done in a safe location with regard for the safety of all personnel General Since weather conditions and terrain frequently vary no specific braking...

Page 83: ...s indicated in BRAKE DRUM REMOVAL and BRAKE SHOE REMOVAL sections Clean and inspect all brake parts If there is evidence of rust or if the lever slide mechanism does not move smoothly in the backing p...

Page 84: ...up the braking surface Slight scores in the drum brake surface may be removed by lightly polishing with a fine emery cloth An extensively scored drum will cause excessive brake lining wear and must b...

Page 85: ...s turn the retainer spring 1 4 turn to align the slot in the spring retainer with the flats on the tension spring Do not turn the pins as their seal may be broken Remove the brake shoe retainer spring...

Page 86: ...operating conditions If free movement cannot be obtained with lubrication the entire back plate assembly must be replaced No dis assembly of slide lever mechanism may be accom plished Adjust the brak...

Page 87: ...BRAKES Page J 6 Repair and Service Manual Notes...

Page 88: ...le Shaft Seal Removal and Replacement K 1 Axle Shaft Replacement K 3 LIST OF ILLUSTRATIONS Fig 1 Removing Installing Outer Snap Ring K 1 Fig 2 Removing Installing Axle Shaft K 1 Fig 3 Pressing Bearing...

Page 89: ...REAR AXLE Page K ii Repair and Service Manual Notes...

Page 90: ...fting procedure in SAFETY section of this manual Place wheel chocks in front and behind the front wheels and check the stability of the vehicle on the jack stands before start ing any repair procedure...

Page 91: ...ig 4 on page K 2 Use a puller to remove the seal Ref Fig 5 on page K 2 To install the seal use the special seal installer to drive the seal into its correct position Ref Fig 6 on page K 2 To prevent s...

Page 92: ...l the outer snap ring Coat the outboard spline of the axle with a commercially available anti seize compound Install the brake hub and drum thrust washer nut and new cotter pin Ref Fig 7 on page K 3 T...

Page 93: ...REAR AXLE Page K 4 Repair and Service Manual Read all of Section B and this section before attempting any procedure Pay particular attention to all Notes Cautions and Warnings Notes...

Page 94: ...TABLE OF CONTENTS FOR SECTION L SECTION TITLE PAGE NO Page L i Repair and Service Manual L PAINT PAINTING L 1 Minor Scratches L 1 Larger Scratches L 1 Complete Panel Repair L 1...

Page 95: ...PAINT Page L ii Repair and Service Manual Notes...

Page 96: ...ew and protect depth of finish VI Wax or polish with Carnauba base product avail able at any automotive parts distributor Larger Scratches For larger scratches the following steps be taken to repair t...

Page 97: ...PAINT Page L 2 4GRCKT CPF 5GTXKEG CPWCN 4GCF CNN QH 5GEVKQP CPF VJKU UGEVKQP DGHQTG CVVGORVKPI CP RTQEGFWTG 2C RCTVKEWNCT CVVGPVKQP VQ CNN 0QVGU CWVKQPU CPF 9CTPKPIU Notes...

Page 98: ...ING Grounding Requirements M 1 Ground Systems M 1 Lightning Protection Requirements M 1 Equipment Fault and Personal Safety System M 1 Ground Network Requirements M 1 External Grounding Requirements M...

Page 99: ...LIGHTNING PROTECTION AND GROUNDING Page M ii Repair and Service Manual Notes...

Page 100: ...resistivity rock formations or other abnormal conditions alternate methods for reducing the resistance to earth must be considered Chemical Treatments No salt coke or other chemicals may be used to tr...

Page 101: ...ter of the struc ture Ground Loop Conductor In no case shall the ground loop conductor be smaller than a 2 0 AWG bare stranded soft drawn copper wire The ground loop must be installed at least 24 belo...

Page 102: ...with the AC power distribution conductors There shall be no green wires spliced within the conduit All splices shall be performed at the appropriate junction boxes Bond the ground conductor to all pu...

Page 103: ...ISION A SUPERCEDES TITLE General Specification Lightning Protection and Grounding Rev ECN 027194 LIGHTNING PROTECTION AND GROUNDING Read all of Section B and this section before attempting any procedu...

Page 104: ...N i Repair and Service Manual N GENERAL SPECIFICATIONS ELECTRIC POWERED THREE WHEEL SERVICE VEHICLE N 1 LIST OF ILLUSTRATIONS Fig 1 Vehicle Dimensions and Incline Specifications N 2 Fig 2 Vehicle Turn...

Page 105: ...GENERAL SPECIFICATIONS Page N ii Repair and Service Manual Notes...

Page 106: ...senger TOTAL LOAD CAPACITY Includes operator cargo 450 lbs 204 kg SPEED 11 mph 18 kph CHASSIS Welded tubular steel powder coated Durashield VEHICLE PROTECTION None BODY Diamond pattern body with Duras...

Page 107: ...ONS Fig 1 Vehicle Dimensions and Incline Specifications RECOMMENDED MAXIMUM RAMP GRADE 25 or 14 MAXIMUM RECOMMENDED MAXIMUM SIDE TILT 25 or 14 MAXIMUM 22 75 in 58 cm 28 5 in 73 cm 30 in 76 cm 25 8 in...

Page 108: ...e Manual GENERAL SPECIFICATIONS Fig 2 Vehicle Turning Clearance Diameter and Intersecting Aisle Clearance TURNING CLEARANCE DIAMETER 54 in 137 cm 54 in 137 cm INTERSECTING AISLE CLEARANCE 130 in 330 c...

Page 109: ...Page N 4 Repair and Service Manual GENERAL SPECIFICATIONS Notes...

Page 110: ...Installation P 2 Bearing Adjustment P 2 Fork Bearing Inspection P 3 Wheel Steering P 4 Gear Drive Adjustment P 4 Disassembly And Repair P 4 SPRINGS P 5 Front Springs P 5 Rear Springs P 6 Shock Absorb...

Page 111: ...STEERING Page P ii Repair and Service Manual Notes...

Page 112: ...wrench 1 1 8 2 Socket 1 1 8 1 2 drive 1 Ratchet 3 8 drive 1 Ratchet 1 2 drive 1 Framing square 1 While holding nut item 1 remove nut item 2 securing axle item 3 to front fork item 4 Ref Fig 1 on page...

Page 113: ...a grease gun be used however manual packing is acceptable if done correctly Packing a bearing manually requires placing a dab of grease in the palm of the hand and dipping the bearing in the grease F...

Page 114: ...item 4 Remove the jam nut item 5 spindle nut item 6 and remove fork assembly item 7 The bushings item 8 may now be removed Inspect the fork assembly shaft item 7 and the bushings item 8 for excessive...

Page 115: ...Nm torque 6 Check the steering for free operation A slight amount of roughness is permitted after the front fork and wheel has rotated either direction 15 degrees It is better to have the allowable ro...

Page 116: ...e three screws attaching the lower housing until a smooth turning fork is achieved Tighten the hardware securing the lower housing to the support brackets to 3 4 lbs ft 4Nm 5Nm torque and recheck by r...

Page 117: ...the nuts which secure the spring retainers to the vehicle body 6 To reinstall insert the upper spring retainer disks into the top ends of the springs Turn them until the end of the spring coil extend...

Page 118: ...ponents will eventually fail to perform properly as the result of normal use age wear or abuse It is virtually impossible to anticipate all possible compo nent failures or the manner in which each com...

Page 119: ...ithout the express permission of E Z GO Division of Textron Inc Technical Communications Department Cushman Products 1451 Marvin Griffin Road Georgia 30903 3852 USA Inside USA Phone 1 800 241 5855 FAX...

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