Cushman MINUTE MISER Technician's Repair And Service Manual
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Cushman MINUTE MISER Technician's Repair And Service Manual

Electric powered three wheel service vehicle
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600198-G01
TECHNICIAN'S REPAIR
AND SERVICE MANUAL
ELECTRIC POWERED THREE WHEEL
SERVICE VEHICLE
ISSUED NOVEMBER 2003
REVISED FEBRUARY 2007

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  • Page 1 600198-G01 TECHNICIAN’S REPAIR AND SERVICE MANUAL ELECTRIC POWERED THREE WHEEL SERVICE VEHICLE ISSUED NOVEMBER 2003 REVISED FEBRUARY 2007...
  • Page 2 SAFETY Read and understand all labels located on the vehicle. For any questions on any of the information, contact a represen- tative for clarification. 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 control and possible serious injury, speeds should be limited to no more than the maximum speed on level ground (See GENERAL SPECIFICATIONS).
  • Page 3 SERVICE VEHICLE VEHICLES ™ CUSHMAN MINUTE MISER STARTING MODEL YEAR : 2004 E-Z-GO Division of Textron Inc., 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.
  • Page 4 NOTES To obtain a copy of the limited warranty applicable to the vehicle, call or write a local Distributor, an authorized Branch or the Warranty Department with vehicle serial number and manufacturer code. The use of non Original Equipment Manufacturer (OEM) parts may void the warranty. Overfilling of batteries may void the warranty.
  • Page 5 NOTES To obtain a copy of the limited warranty applicable to the vehicle, call or write a local Distributor, an authorized Branch or the Warranty Department with vehicle serial number and manufacturer code. The use of non Original Equipment Manufacturer (OEM) parts may void the warranty. Overfilling of batteries may void the warranty.

  • Page 6: Table Of Contents

    TABLE OF CONTENTS TITLE PAGE Safety ........................... Inside Covers General Information...........................ii Safety Information ..........................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 Brakes ..............................
  • Page 7 TABLE OF CONTENTS Notes: Repair and Service Manual Page iv...

  • Page 8: Safety Information

    SAFETY INFORMATION This manual has been designed to assist the owner-operator in maintaining the vehicle in accordance with procedures developed by the manufacturer. Adherence to these procedures and troubleshooting tips will ensure the best possible service from the product. To reduce the chance of personal injury and/or property damage, the following instructions must be carefully observed: GENERAL Many vehicles are used for a variety of tasks beyond the original intended use of the vehicle;...
  • Page 9 SAFETY INFORMATION Always reduce speed to compensate for poor terrain or conditions. Always apply service brake to control speed on steep grades. Always maintain adequate distance between vehicles. Always reduce speed in wet areas. Always use extreme caution when approaching sharp or blind turns. Always use extreme caution when driving over loose terrain.
  • Page 10 SAFETY INFORMATION VENTILATION Hydrogen gas is generated in the charging cycle of batteries and is explosive in concentrations as low as 4%. Because hydrogen gas is lighter than air, it will collect in the ceiling of buildings necessitating proper ventilation. Five air exchanges per hour is considered the minimum requirement.
  • Page 11 SAFETY INFORMATION Notes: Owner’s Manual and Service Guide Page viii...
  • Page 12 GENERAL INFORMATION & ROUTINE MAINTENANCE TABLE OF CONTENTS FOR SECTION ‘A’ SECTION TITLE PAGE NO. SERIAL NUMBER LABEL LOCATION ....................A - 1 SERVICING THE VEHICLE ......................A - 1 ROUTINE MAINTENANCE ......................A - 2 REAR AXLE .............................A - 2 Checking the Lubricant Level ....................A - 2 BRAKES............................A - 2 TIRES...............................A - 3 LIGHT BULB REPLACEMENT ......................A - 3...
  • Page 13 GENERAL INFORMATION & ROUTINE MAINTENANCE TABLE OF CONTENTS FOR SECTION ‘A’ SECTION TITLE PAGE NO. 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.

  • Page 14: Serial Number Label Location

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings SERIAL NUMBER LABEL LOCATION SERVICING THE VEHICLE To prevent severe injury The product model number, model year and serial num- or death resulting from ber must appear on all correspondence concerning this improper servicing tech-...

  • Page 15: Routine Maintenance

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings In order to prevent damage to the bat- Do not use more than three (3) pumps tery charger transformer, blow water of grease in each grease fitting at any from charger with compressed air.

  • Page 16: Light Bulb Replacement

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings After the vehicle has been put into service, it is recom- For information on conducting a brake test, refer to mended that the brakes be checked daily by performing BRAKES section.

  • Page 17: Vehicle Care Products

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings • Rubber parts should be cleaned with non-abrasive Battery Maintenance Kit for complete battery household cleaner.

  • Page 18: Key Switch

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Controls (Ref Fig. 9 on page A-5) and (Ref Fig. 10 on page A-5) Controls on the dash and the floorboard.

  • Page 19: Direction Selector Switch

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings positions. Push to the NEUTRAL position when leaving the vehicle seat. DEPRESS TO ENGAGE PARKING BRAKE CATCH DEPRESS TO RELEASE PARKING...

  • Page 20: Handlebar Installation

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Handlebar Installation Battery Charger If the handlebar is factory installed, The standard vehicle is equipped with a built-in 24 volt, make sure the retaining nut is tight.

  • Page 21: Programmable Speed Controller

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings To prevent possible inju- To reduce the possibility ry, make sure the seat is of severe injury or death in the lowered position resulting from loss of...

  • Page 22: Starting The Vehicle

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings STARTING THE VEHICLE COASTING To start the vehicle: Place the key in the key switch and T o p r e v e n t i n j u r y o r turn to the ‘ON’...
  • Page 23 GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings PERIODIC SERVICE SCHEDULE ✓ Check ♦ Clean, Adjust, etc. ▲ Replace NOTE: Some maintenance items must be serviced more frequently on vehicles used under severe driving conditions DAILY ♦...
  • Page 24 GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings SEMI-ANNUAL - 125 HOURS (includes items listed in previous tables & the following) ♦ Clean and adjust, see Technician’s Repair and Service Manual SERVICE / PARK BRAKES ✓...
  • Page 25 GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Notes: Repair and Service Manual Page A-12...

  • Page 26: Safety

    SAFETY TABLE OF CONTENTS FOR SECTION ‘B’ SECTION TITLE PAGE NO. GENERAL ............................B - 1 NOTES, 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 Notes: Repair and Service Manual Page B-ii...

  • Page 28: General

    SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings GENERAL manual without the manufacturer’s prior written authori- zation. Where authorized modifications have been made, The following text is provided as recommended by part II the user shall ensure that capacity, operation, warning, of ASME/ANSI B56.8-1988.
  • Page 29 SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Control of Noxious Gases and Fumes turer; 4.8.1 When equipment powered by internal com- (b) emphasis on safety of passengers, material loads, bustion engines is used in enclosed areas, the atmo- carrier operator, and other employees;...
  • Page 30 SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings 5.4.9 Carriers shall not be parked or left unattended smooth, sweeping motion. such that they block or obstruct fire aisles, access to Loading stairways, or fire equipment.
  • Page 31 SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Maintenance Procedures prevent the use of the carrier until the leak has been eliminated. 6.2.1 Maintenance and inspection of all carriers (o) The carrier manufacturer’s capacity, operation, and shall be performed in conformance with the manufac- maintenance instruction plates, tags, or decals shall be...

  • Page 32: Notes, Cautions And Warnings

    SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings NOTES, CAUTIONS AND WARNINGS mechanic and bystanders if not treated with utmost cau- tion. Be careful not to place hands, face, feet or body in a Throughout this manual, the following NOTES, CAU- location that could expose them to injury should an TIONS and WARNINGS are used.

  • Page 33: Before Servicing The Vehicle

    SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings BEFORE SERVICING THE VEHICLE sitating proper ventilation. Five air exchanges per hour is considered the minimum requirement. Before attempting to inspect or service a vehicle, be sure Be sure that the key switch is off and all electrical to read and understand the following warnings: accessories are turned off before starting work on...

  • Page 34: Lifting The Vehicle

    SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings LIFTING THE VEHICLE Do not lift the rear of the vehicle without stabilizing the front of the vehicle. To raise the rear of the vehicle, posi- Tool List Qty.

  • Page 35: Standards And Publications

    SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings STANDARDS AND PUBLICATIONS This Electric Vehicle complies with ANSI B56.8 as it applies to OSHA for Powered Industrial Trucks under the This unit is not a motor vehicle within the definition of the Type E and EE classifications.

  • Page 36: Body

    BODY TABLE OF CONTENTS FOR SECTION ‘C’ SECTION TITLE PAGE NO. 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 Repair and Service Manual Page C-i...
  • Page 37 BODY Notes: Repair and Service Manual Page C-ii...
  • Page 38 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings BODY In the following text, there are references to Drill Out Rivet removing/installing bolts etc. Additional hard- Pop Rivet Head Only ware (nuts, washers etc.) that are removed must always be installed in their original positions unless otherwise specified.
  • Page 39 BODY 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 Repair and Service Manual Page C-2...

  • Page 40: Wheels And Tires

    WHEELS AND TIRES TABLE OF CONTENTS FOR SECTION ‘D’ SECTION TITLE PAGE NO. 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...................
  • Page 41 WHEELS AND TIRES Notes: Repair and Service Manual Page D-ii...
  • Page 42 WHEELS AND TIRES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings WHEEL AND TIRE SERVICE Tire Repair The vehicle is fitted with low pressure tubeless tires Tools List Qty.
  • Page 43 WHEELS AND TIRES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings 'Cross Sequence' Tire style may vary Fig. 1 Wheel Installation Install the wheel assembly with the valve stem on the same side as the wheel retaining nuts.
  • Page 44 BATTERIES AND CHARGING TABLE OF CONTENTS FOR SECTION ‘E’ SECTION TITLE PAGE NO. BATTERIES AND CHARGING ......................E - 1 Safety ............................E - 1 BATTERY............................E - 1 BATTERY MAINTENANCE......................E - 1 At Each Charging Cycle ......................E - 2 Monthly ..........................E - 2 Electrolyte Level and Water....................E - 2 Cleaning Batteries .........................E - 3 Battery Replacement ......................E - 3...

  • Page 45: Batteries And Charging

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

  • Page 46: Safety

    BATTERIES AND CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings BATTERIES AND CHARGING Wr ap wr e n c h es w i t h vinyl tape to prevent the Safety possibility of a dropped wrench from ‘shorting...

  • Page 47: At Each Charging Cycle

    BATTERIES AND CHARGING Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings At Each Charging Cycle and the increase in volume of the electrolyte that results from the charging cycle. To reduce the possibility Do not overfill batteries.

  • Page 48: Cleaning Batteries

    BATTERIES AND CHARGING Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings approved water source (Ref Fig. 3 on page E-3). These ml) of sodium bicarbonate (baking soda) mixed with 1 1/2 watering devices are fast and accurate to use and gallons (6 liters) of clear water (Ref Fig.

  • Page 49: Prolonged Storage

    BATTERIES AND CHARGING Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings The batteries should be placed into the battery racks and lose .002 of specific gravity each day. If a fully charged the battery hold downs tightened to 45 - 55 in.

  • Page 50: Battery Charging

    BATTERIES AND CHARGING Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Battery Charging The second reason is to determine why a particular vehi- cle does not perform adequately. Performance problems The battery charger is designed to fully charge the bat- may result in a vehicle that runs slowly or in a vehicle that tery set.

  • Page 51: Using A Hydrometer

    BATTERIES AND CHARGING Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings 4. Add or subtract four points (.004) to the reading for Bulb every 10° F (6° C) the electrolyte temperature is Cylinder Float above or below 80°...
  • Page 52 BATTERIES AND CHARGING Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings 5. Test each cell and note the readings (corrected to 80° F or 27° C). A variation of fifty points between any two cell readings (example 1.250 - 1.200) indicates a problem with the low reading cell(s).
  • Page 53 BATTERIES AND CHARGING Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Notes: Owner’s Manual and Service Guide Page E-8...

  • Page 54: Electronic Speed Control

    ELECTRONIC SPEED CONTROL TABLE OF CONTENTS FOR SECTION ‘F’ SECTION TITLE PAGE NO. 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 Indicator.....................F - 1 Fig.
  • Page 55 ELECTRONIC SPEED CONTROL Notes: Repair and Service Manual Page F-ii...
  • Page 56 ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings PROGRAMMABLE SPEED CONTROLLER The vehicle is equipped with an electronic speed control- ler that does not require servicing. Some controllers may not have current and speed limit adjustment.
  • Page 57 ELECTRONIC SPEED CONTROL Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings TROUBLESHOOTING CHART PROGRAMMER LCD DISPLAY EXPLANATION POSSIBLE CAUSE CODE HW FAILSAFE hardware fail-safe error 1. Controller defective. 1.
  • Page 58 ELECTRONIC SPEED CONTROL Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings 1. Temperature >85°C or <-25 °C. 2. Excessive load on vehicle. THERMAL CUTBACK over/under-temp. cutback 3. Improper mounting of controller. 4.
  • Page 59 ELECTRONIC SPEED CONTROL Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings E-Z-GO FACTORY SET CONTROLLER PARAMETERS PARAMATER RANGE DEFAULT DESIRED UNITS DESCRIPTION Current Limit, Main 20 - 250 Amps Maximum current forward speed Current Limit, Low Speed...

  • Page 60: Motor

    MOTOR TABLE OF CONTENTS FOR SECTION ‘G’ SECTION TITLE PAGE NO. GENERAL ............................G - 1 Motor Removal ........................G - 1 Motor Disassembly ......................G - 1 Bearing Replacement ......................G - 1 Brush Replacement ......................G - 2 Motor Assembly........................
  • Page 61 MOTOR Notes: Repair and Service Manual Page G-ii...
  • Page 62 MOTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings GENERAL Do not hold vehicle on hill by using accelerator and motor. Leaving the motor in a stalled condition for more than 3-4 seconds will raise the commutator bars resulting in unacceptable noise and accel- erated brush wear and cause permanent damage to motor.
  • Page 63 MOTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Fig. 3 Motor Components To aid disassembly, heat only the commutator end cover When installing armature into the bear- before attempting removal of the armature.
  • Page 64 MOTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Motor Tests The field coil and motor housing are not available as indi- vidual parts. No testing is recommended to determine the specific area of failure.
  • Page 65 MOTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Notes: Repair and Service Manual Page G-4...
  • Page 66 ELECTRICAL SYSTEM AND BATTERY CHARGER TABLE OF CONTENTS FOR SECTION ‘H’ SECTION TITLE PAGE NO. TROUBLESHOOTING VEHICLE WIRING ..................H - 1 Symptoms..........................H - 1 Testing..........................H - 1 Testing Battery Voltage ......................H - 1 Continuity Check ........................H - 1 Testing a Switch for Continuity .....................
  • Page 67 ELECTRICAL SYSTEM AND BATTERY CHARGER Notes: Repair and Service Manual Page H-ii...

  • Page 68: Troubleshooting Vehicle Wiring

    ELECTRICAL SYSTEM AND BATTERY CHARGER Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings TROUBLESHOOTING VEHICLE WIRING connectors may be indicated by readings that may be up to one volt less than the reference voltage. No reading Tool List Qty.

  • Page 69: Testing A Switch For Continuity

    ELECTRICAL SYSTEM AND BATTERY CHARGER Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Testing a Switch for Continuity Place one probe on one contact of the switch, place the second probe on the second terminal of the switch (Ref Fig.
  • Page 70 ELECTRICAL SYSTEM AND BATTERY CHARGER Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings DIRECTION SWITCH REVERSE BUZZER WHT/BLU WHT/GRN WHT/BLU WHT/BLU CONTROLLER TO TEST POTENTIOMETER: SET DVOM TO KW SCALE AND CHECK BETWEEN WHITE AND YELLOW WIRES.
  • Page 71 ELECTRICAL SYSTEM AND BATTERY CHARGER Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings WHT/GRN WHT/BLU REVERSE FORWARD SOLENOID SOLENOID MOTOR WHT/BLU WHT/GRN WHT/RED BRAKE SWITCH TAIL & BRAKE LIGHT LIGHT SWITCH HOUR METER...
  • Page 72 MAIN CONTACTOR 830640 24 V 841208 A - YEL POTENTIOMETER AY B - WHT 892894 C - BLU HORN BUTTON 806791 MOTOR MINUTE MISER 892671 BATT HORN WHT/BLU 886090 SEAT SWITCH AY WHT/BLU 158135 -01 KEY SWITCH 886311 REVERSE DIRECTION SWITCH...

  • Page 73: Vehicle Moves When Selector Is Turned On

    ELECTRICAL SYSTEM AND BATTERY CHARGER Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Vehicle Moves When Selector Is Turned On symptoms with their associated test procedures and remedies: Possible Causes Remedy...

  • Page 74: Charger Dc Fuse Blows

    ELECTRICAL SYSTEM AND BATTERY CHARGER Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings The most probable cause is one diode shorting and blowing one fuse. Refer to “Charger DC Fuse Blows” for procedures to check the diodes.

  • Page 75: Testing The Charger

    ELECTRICAL SYSTEM AND BATTERY CHARGER Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings 2. Place a jumper wire between #1 and #3 on the elec- 2. Disconnect the DC output leads from the batteries. tronic timer.

  • Page 76: Capacitor Quick Test

    ELECTRICAL SYSTEM AND BATTERY CHARGER Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Capacitor Quick Test Darkening of all the transformer secondary coil windings is an indication of possible over heating damage. A low NEVER touch capacitor or complete lack of output would be observed on the terminals with uninsulat-...

  • Page 77: Open Circuit Transformer Test

    ELECTRICAL SYSTEM AND BATTERY CHARGER Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Some transformer leads may be aluminum wire all the transformer secondary coil windings is an indica- and a solder must be used on these wires that tion of possible over heating damage.
  • Page 78 ELECTRICAL SYSTEM AND BATTERY CHARGER Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings CONTROLLER KIT SECONDARY COIL JUMPER SECONDARY CHARGER COIL VOLTS NAME PLATE RATING CAPACITOR SECONDARY COIL VOLTS TEST POINTS PRIMARY...
  • Page 79 ELECTRICAL SYSTEM AND BATTERY CHARGER Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Notes: Repair and Service Manual Page H-12...

  • Page 80: Brakes

    BRAKES TABLE OF CONTENTS FOR SECTION ‘J’ SECTION TITLE PAGE NO. GENERAL ............................J - 1 DAILY BRAKE PERFORMANCE TEST................... J - 1 General ..........................J - 1 Test Method........................... J - 1 SIX MONTH BRAKE SYSTEM MAINTENANCE ................J - 2 HOW THE SERVICE BRAKE WORKS....................
  • Page 81 BRAKES Notes: Repair and Service Manual Page J-ii...

  • Page 82: General

    BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, To assure correct braking performance, all peri- odic maintenance, inspections and procedures must be performed as indicated in the Periodic Service Sched- ule in Section ‘A’...

  • Page 83: Six Month Brake System Maintenance

    BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings The mechanic should perform a ‘panic stop’ by applying HOW THE SERVICE BRAKE WORKS maximum force and travel to the service brake pedal while moving at full speed.

  • Page 84: How The Paking Brake Works

    BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings strap permit the brake levers to release fully when the brake is applied until the notch in the latch arm engages brake pedal is in the released position.

  • Page 85: Brakes

    BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings the braking surface. It is recommended that a suitable greaseless type sol- Heavy Shoe Spring vent be used to clean the braking surface of brake drums Tension Pin before they are placed in service to assure the cleanest possible surface.

  • Page 86: Brake Adjustment

    BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings To remove the brake assembly for axle or seal replace- ment, the brake must be removed. Raise the vehicle and support on jack stands.
  • Page 87 BRAKES Notes: Repair and Service Manual Page J-6...

  • Page 88: Rear Axle

    REAR AXLE TABLE OF CONTENTS FOR SECTION ‘K’ SECTION TITLE PAGE NO. REAR AXLE DISASSEMBLY......................K - 1 Axle Shaft Removal and Disassembly...................K - 1 Axle Shaft Seal Removal and Replacement................K - 1 Axle Shaft Replacement ......................K - 3 LIST OF ILLUSTRATIONS Fig.
  • Page 89 REAR AXLE Notes: Repair and Service Manual Page K-ii...

  • Page 90: Rear Axle

    REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings REAR AXLE DISASSEMBLY The rear axle is a precision assembly, and therefore any repair or replacement of parts must be done with extreme care in a clean environment. Before attempting to perform any service on the axle, read and understand all of the following text and illustrations before dis- assembling the unit.
  • Page 91 REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Bearing Separator Fig. 3 Pressing Bearing from Axle Shaft Fig. 5 Removing Seal Use care to prevent damage to the inner surface of the axle tube at the sealing area.
  • Page 92 REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Axle Shaft Replacement Carefully insert the axle shaft and bearing through the oil seal. Rotate the shaft until the spline engages with the differential side gears.
  • Page 93 REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Notes: Repair and Service Manual Page K-4...

  • Page 94: Paint

    PAINT TABLE OF CONTENTS FOR SECTION ‘L’ SECTION TITLE PAGE NO. PAINTING ............................L - 1 Minor Scratches........................L - 1 Larger Scratches ........................L - 1 Complete Panel Repair ......................L - 1 Repair and Service Manual Page L-i...
  • Page 95 PAINT Notes: Repair and Service Manual Page L-ii...
  • Page 96 PAINT G C F C N N Q H 5 G E V K Q P $ C P F V J K U U G E V K Q P D G H Q T G C V V G O R V K P I C P [ R T Q E G F W T G  2 C [ R C T V K E W N C T C V V G P V K Q P V Q C N N 0 Q V G U  % C W V K Q P U C P F 9 C T P K P I U 2#+06+0) Mask the area to be painted (common masking tape is adequate) prior to repair and use aerosol type...
  • Page 97 PAINT G C F C N N Q H 5 G E V K Q P $ C P F V J K U U G E V K Q P D G H Q T G C V V G O R V K P I C P [ R T Q E G F W T G  2 C [ R C T V K E W N C T C V V G P V K Q P V Q C N N 0 Q V G U  % C W V K Q P U C P F 9 C T P K P I U Notes: 4GRCKT CPF 5GTXKEG /CPWCN Page L-2...

  • Page 98: Lightning Protection And Grounding

    LIGHTNING PROTECTION AND GROUNDING TABLE OF CONTENTS FOR SECTION ‘M’ SECTION TITLE PAGE NO. Grounding Requirements ....................... M - 1 Ground Systems ..........................M - 1 Lightning Protection Requirements ....................M - 1 Equipment Fault and Personal Safety System ................M - 1 Ground Network Requirements ......................
  • Page 99 LIGHTNING PROTECTION AND GROUNDING Notes: Repair and Service Manual Page M-ii...

  • Page 100: Grounding Requirements

    LIGHTNING PROTECTION AND GROUNDING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings REVISION: GS-726-006 TITLE: General Specification: Lightning Protection and Grounding EFFECTIVE: SUPERCEDES: Rev -, ECN 027194 10/19/92 1.

  • Page 101: External Grounding Requirements

    LIGHTNING PROTECTION AND GROUNDING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings REVISION: GS-726-006 TITLE: General Specification: Lightning Protection and Grounding SUPERCEDES: EFFECTIVE: Rev -, ECN 027194 10/19/92 6.

  • Page 102: Lightning Protection System

    LIGHTING PROTECTION AND GROUNDING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings REVISION: GS-726-006 TITLE: General Specification: Lightning Protection and Grounding SUPERCEDES: EFFECTIVE: Rev -, ECN 027194 10/19/92 9.
  • Page 103 LIGHTNING PROTECTION AND GROUNDING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings REVISION: GS-726-006 TITLE: General Specification: Lightning Protection and Grounding SUPERCEDES: EFFECTIVE: Rev -, ECN 027194 10/19/92 Notes: Repair and Service Manual...

  • Page 104: General Specifications

    GENERAL SPECIFICATIONS TABLE OF CONTENTS FOR SECTION ‘N’ SECTION TITLE PAGE NO. ELECTRIC POWERED THREE WHEEL SERVICE VEHICLE............N - 1 LIST OF ILLUSTRATIONS Fig. 1 Vehicle Dimensions and Incline Specifications ..............N - 2 Fig. 2 Vehicle Turning Clearance Diameter and Intersecting Aisle Clearance....... N - 3 Repair and Service Manual Page N-i...
  • Page 105 GENERAL SPECIFICATIONS Notes: Repair and Service Manual Page N-ii...
  • Page 106 GENERAL SPECIFICATIONS ELECTRIC POWERED THREE WHEEL SERVICE VEHICLE BATTERY MONITORING ..........LED State of charge meter BATTERIES ...............Four 6 volt deep cycle (105 minute minimum, 180 amp-hour @ 20 hour discharge rate) SPEED CONTROLLER .............Programmable Solid state, 250 amp capacity MOTOR ................24 VDC, series wound 1.5 hp (1.1 kW) @ 2800 rpm & 4.3 hp (3.2 kW) @ 1600 rpm, brazed armature and solid copper windings REAR AXLE ..............Bevel gear with spur and helical gear reduction BRAKES ................Dual rear wheel, self adjusting mechanical drum brakes...
  • Page 107 GENERAL SPECIFICATIONS 22.75 in (58 cm) 28.5 in (73 cm) 39 in 4 in (99 cm) (10 cm) 25.8 in 53 in (65 cm) (135 cm) 30 in 85 in (216 cm) (76 cm) RECOMMENDED MAXIMUM RAMP GRADE RECOMMENDED MAXIMUM SIDE TILT 25% or 14˚...
  • Page 108 GENERAL SPECIFICATIONS TURNING CLEARANCE DIAMETER 130 in (330 cm) (Handlebar) 154 in (391 cm) 54 in. (137 cm) INTERSECTING AISLE CLEARANCE 54 in (137 cm) Fig. 2 Vehicle Turning Clearance Diameter and Intersecting Aisle Clearance Repair and Service Manual Page N-3...
  • Page 109 GENERAL SPECIFICATIONS Notes: Repair and Service Manual Page N-4...

  • Page 110: Steering And Suspension

    STEERING AND SUSPENSION TABLE OF CONTENTS FOR SECTION ‘P’ SECTION TITLE PAGE NO. STEERING ............................P - 1 HANDLEBAR STEERING ........................P - 1 FRONT WHEEL ..........................P - 1 Front Wheel Removal......................P - 1 Front Wheel Installation......................P - 1 MAINTENANCE ..........................P - 1 Lubrication ..........................P - 1 Wheel Bearing Inspection......................P - 2 Packing Wheel Bearings .......................P - 2...
  • Page 111 STEERING Notes: Repair and Service Manual Page P-ii...

  • Page 112: Fig. 7 Lubrication

    STEERING AND SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings STEERING Front Wheel Installation Front wheel installation is the reverse order of removal. In the following text, there are references to With vehicle sitting on a level surface, adjust front axle so removing/installing bolts etc.
  • Page 113 STEERING AND SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Lubricate vehicle per schedule contained in Section ‘A’. that a bearing packer attached to a grease gun be used; however, manual packing is acceptable if done correctly.
  • Page 114 STEERING AND SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings moves freely but without vertical motion. Tighten the jam nut (item 5) firmly and confirm that the adjustment is still satisfactory.
  • Page 115 STEERING AND SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Wheel Steering Gear Drive Adjustment Normal wear of steering parts will require backlash adjustment only. Adjust backlash as follows: 1.
  • Page 116 STEERING AND SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings 5. Replace worn gears as required. Replace the roll pin ets; however, when adjustment is required, it may be in the sector gear or driven gear, if required, to pro- necessary to remove the upper housing assembly vide adequate stops as the steering wheel is turned.
  • Page 117 STEERING AND SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings 2. Loosen the axle nuts and lower the entire wheel, hub and axle assembly from the front fork. 3.
  • Page 118 Read and understand the following warnings Read and understand the following text and before attempting to operate the vehicle: warnings before attempting to service vehicle: In any product, components will eventually fail to perform properly as the result of normal use, age, wear or abuse. prevent personal It is virtually impossible to anticipate all possible compo-...
  • Page 119 Cushman Products 1451 Marvin Griffin Road, Georgia 30903-3852 USA Inside USA Phone: 1-800-241-5855, FAX: 1-800-448-8124 Outside USA Phone: 010-1-706-798-4311, FAX: 010-1-706-771-4609 Copyrighted Material This manual may not be reproduced in whole or in part without the express permission of E-Z-GO Division of Textron Inc.

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