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ELECTRICAL SYSTEM AND BATTERY CHARGER

Page H-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

Fig. 4 Wiring Diagram (Cont.)

BRN

WHT/BLU

WHT/GRN

WHT/BLU

WHT/RED

BLU

WHT

YEL

GRN

ORN

BLK

GRN

MOTOR

REVERSE
SOLENOID

FORWARD
SOLENOID

BLU

RED

BLK

RED

BRAKE
SWITCH

WHT/BLU

ORN

BRN

BLU

WHT

HEADLIGHT

TAIL & BRAKE LIGHT

HORN

HOUR
METER

HORN SWITCH

LIGHT SWITCH

WHT/GRN

Содержание MINUTE MISER

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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