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MINUTE MISER
Cushman MINUTE MISER Service Manual
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ELECTRIC POWERED THREE WHEEL
SER
VICE VEHICLE
ISSUED NOVEMBER 2003
REVISED FEBRUARY 2007
TECHNICIAN’S REP
AIR
AND SER
VICE MANUAL
600198-G01
2
Table of Contents
Table of Contents
6
Safety Information
8
General Information & Routine Maintenance
12
Fig. 1 Model Number, Model Year and Serial Number
14
Fig. 2 Serial Numbers under Seat
14
Fig. 3 Initial Service Chart
14
Serial Number Label Location
14
Servicing the Vehicle
14
Fig. 4 Lubrication Points
15
Fig. 5 Rear Axle Lubricant Check and Fill
15
Routine Maintenance
15
Checking the Lubricant Level
15
Care and Cleaning of the Vehicle
16
Fig. 6 Brake Bushing Lubrication
16
Light Bulb Replacement
16
Fig. 8 Bolt Grades
17
Key Switch
18
Vehicle Care Products
17
Fig. 10 Controls on Floorboard
18
Fig. 11 Horn Switch
18
Direction Selector Switch
19
Power On/Battery Condition Meter
19
Service/Parking Brake Pedal
19
Accelerator Pedal
19
Horn and Handlebar
19
Handlebar Installation
20
Seat Switch
20
Hour Meter (Accessory)
20
Fig. 9 Controls on Dashboard
18
Additional Features
20
Battery Charger
20
Fold down Backrest
20
Programmable Speed Controller
21
Before Entering Vehicle
21
Ee Units
21
Operating the Vehicle
21
Coasting
22
Starting the Vehicle
22
Safety
26
General
28
General Maintenance
32
Important Safety Warning
32
Modifications to Vehicle
32
Notes, Cautions and Warnings
32
Before Servicing the Vehicle
33
Additional Warnings
33
Lifting the Vehicle
34
Towing
34
Standards and Publications
35
Standards
35
Publications
35
Body
36
Wheels and Tires
40
Batteries and Charging
44
Batteries and Charging
45
Safety
46
Battery
46
Battery Maintenance
46
At each Charging Cycle
47
Monthly
47
Electrolyte Level and Water
47
Cleaning Batteries
48
Battery Replacement
48
Prolonged Storage
49
Battery Charging
50
AC Voltage
50
Troubleshooting
50
Hydrometer
50
Using a Hydrometer
51
Electronic Speed Control
54
Motor
60
Electrical System and Battery Charger
66
Troubleshooting Vehicle Wiring
68
Testing
68
Testing Battery Voltage
68
Continuity Check
68
Testing a Switch for Continuity
69
Vehicle Moves When Selector Is Turned on
73
Troubleshooting will Not Run very Far
73
Solenoid Burns up
73
Battery Charger
73
Transformer Hums, but Batteries will Not Take a Charge
73
DC Circuit Continuity Test
73
Charger DC Fuse Blows
74
Electronic Timer Testing
74
Testing the Charger
75
The Transformer Is Silent
75
An AC Line Fuse or Circuit Breaker Blows
75
Capacitor Quick Test
76
The Transformer Has a Short or Burn-Out
76
Open Circuit Transformer Test
77
Brakes
80
Daily Brake Performance Test
82
Test Method
82
General
82
How the Service Brake Works
83
Equalizer Link
83
Automatic Adjuster Mechaninism
83
Six Month Brake System Maintenance
83
Brake Drum and Shoe Removal
84
Brake Drum Removal
84
How the Paking Brake Works
84
Brakes
85
Brake Shoe Removal
85
Brake Removal
85
Brake Adjustment
86
Brake Repair/Replacement
86
Rear Axle
88
Rear Axle
90
Paint
94
Lightning Protection and Grounding
98
Equipment Fault and Personal Safety System
100
Ground Network Requirements
100
Ground Systems
100
Grounding Requirements
100
Lightning Protection Requirements
100
Earth Electrode System
101
External Grounding Requirements
101
Materials
101
10. Equipment Fault and Personal Safety System
102
Lightning Protection System
102
General Specifications
104
Steering and Suspension
110
Fig. 7 Lubrication
112
4
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Cushman MINUTE MISER Specifications
General
Speed
25 mph
Overall Length
120 inches
Overall Width
54 inches
Overall Height
72 inches
Suspension
Leaf Spring
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