American Landmaster 36V 200 Series User manual

15312
Service
Manual
200 Series 36V

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

15312 200 Series 36V
Throttle Sensor Installation ................................................. 7
Throttle Assembly Installation.............................................. 8
Section 6 -Electrical System.................................................. 9
Schematics ................................................................................9
Batteries..................................................................................11
Testing and Water Level.....................................................11
Replacement .....................................................................11
Charging ...........................................................................13
Battery Indicator................................................................13
Section 7 -Chassis ............................................................... 14
Steering Alignment...................................................................14
Section 8 -Brakes ................................................................ 15
Brake System Replacement ......................................................15
Section 9 -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 Switch ..................................................................19
12V Power.........................................................................20
Power Checks: 12V ............................................................20
Battery Checks: Individual Battery ......................................21
Battery Checks: Battery System ..........................................21
Power to Throttle Switch ....................................................22
Controller Power from 36V Harness ....................................22
Relay ................................................................................23
Power Checks: 36 V ...........................................................24
Power to Small Posts of Contactor ......................................25
Controller Power Through Contactor ...................................26
Resistor.............................................................................27
Controller Evaluation..........................................................27

Page 1
200 Series 36V 15312
Section 1 -GENERAL INFORMATION
MODEL IDENTIFICATION
Frame Number
The frame number or VIN
can be found on a plate,
which is located on the
crossbar, behind the seats.
SPECIFICATIONS
DIMENSIONS
Overall Length --------------------------------------------------- 2502mm(98.5inch)
Overall width ------------------------------------------------------ 1245mm (49inch)
Overall height --------------------------------------------------- 1765mm (69.5inch)
Wheelbase ------------------------------------------------------- 1500mm (59.0inch)
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------------------------------------------------------------------ Keyed Electric
Transmission ------------------------------------------------------- Double Belt Drive
Top Speed -----------------------------------------------------------------------20mph
CAPACITIES
Maximum Load (Driver, Passenger, & Gear) ------------------------------- 650lbs
Climbing Angle ------------------------------------------------------------------ 20-25
Batteries -----------------------------------------------------12V Golf Car 155Ah (3)
Head Lights---------------------------------------------------------------12V 35W (2)
Tail Light --------------------------------------------------------------- 12V 21W / 5W
CHASSIS
Brakes (Front and Rear)--------------------------Hydraulic disc/Left foot control
Tires –Front / Rear ------------------- 20 x 7.0-8 @ 15psi / 22×11-10 @ 15psi
VIN Number

15312 200 Series 36V
Suspension-Front ------------------------Dual A-arm with 1.8”(45mm) of travel
Suspension-Rear----------------- Spring over shock with 2.4”(60mm) of travel
WEIGHT
Dry Weight ------------------------------------------------------------408Kg / 975lbs
WARRANTY
Components --------------------------------------------------------------------30 days
Frame ---------------------------------------------------------------------------90 days
Motor and Controller ----------------------------------------------------------- 1 year
* The specifications are subject to change without notice.
Section 2 -MAINTENANCE
PERIODIC CHECKS AND SERVICES
The maintenance intervals in the following table are based upon average riding
conditions. Riding in unusually dusty 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)
I
I
Chassis Lubrication (p. 3)
C, I
L
Belt Tension (p. 4)
I
I
C, A
Motor (p. 4)
C, I
Batteries (p. 4)
I
C, I, A
A: adjust C: clean I: inspect, clean or replace if necessary. L: lubricate R: replace
MAINTENANCE AND TUNE-UP PROCEDURES
This section describes the servicing procedures for each item in the Periodic
Maintenance requirements.
Tire Pressure / Wear
Check the tire pressure every time the kart is ridden. The tire pressure is very
important for the stability of the ride.

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200 Series 36V 15312
Brake Fluid and Performance
Always check that there is plenty of brake fluid
in the brake fluid reservoir.
Ensure brake fluid looks clean and brake hoses
are in good condition
Check that the front (7150 only) and rear
brake pads are in good condition.
Check the brake rotors for abnormal wear.
Chassis Nuts and Bolts
Always pay attention to the karts nuts and bolts. Some loosening after use is
normal and should not be left unchecked for an extended period of time.
TIGHTENING TORQUE CHART
Bolt
Diameter
(mm)
Conventional marked bolt
8.8 marked bolt
N.m
Kg.m
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
10
22 ~35
2.2 ~3.5
16.0~25.5
40 ~60
4.0 ~6.0
29.0 ~43.5
12
35 ~50
3.5 ~5.5
25.5 ~40
70 ~100
7.0 ~10.0
50.5 ~72.5
14
50 ~80
5.0 ~8.0
36.5 ~58
110 ~160
11.0 ~16.0
79.5 ~115.5
16
80 ~130
8.0 ~13.0
58 ~94
170 ~250
17.0 ~25.
123.0 ~181.0
18
130 ~190
13.0~19.0
94 ~137.5
200 ~280
20 ~28.0
144.5 ~202.5
Chassis Lubrication
Clean and Grease chassis bushings and bearings quarterly to assure smooth
operation and extended life of the bushings and the components.
If used in extreme wet and muddy conditions or dusty conditions, it is
recommended more often.
For proper tire pressure ratings,
see Section 1 -Specifications.

15312 200 Series 36V
Inspect components for cracks or abnormal or excessive wear.
Belt Tension
Inspect and adjust belt tension. Refer to Section 4 --Drive System for details.
Motor
Inspect electrical connections to the motor. Tighten loose connections as
specified in Section 3 -Motor removal and Installation.
Inspect motor mounting 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 damage or excessive leaking.
Inspect nut tension and the condition of the cables. If any signs of arching or
wear exist, adjust or replace the affected component.
Inspect water level of each cell of each battery. See Section 6 -
Loose connections in the battery system
can cause serious damage to the
vehicle’s electrical system.

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200 Series 36V 15312
Batteries.
Section 3 -MOTOR AND CONTROLLER
Before servicing the Motor or Motor Controller, be sure to disconnect the Main Fuse.
A charge is stored in the Motor Controller and if its terminals are shorted out, even
though disconnected from the battery, it may spark. This will not cause damage to
the controller.
MOTOR REMOVAL AND INSTALLATION
The motor is isolated from the chassis to ensure arching will not damage the motor
controller. Ensure isolating washers are put back in place after removal.
Motor Removal
To remove the motor:
1. Disconnect the Main Fuse.
2. Using a 2.5mm Allen Wrench, loosen the drive pulley set screw.
3. Loosen the Drive Belt Tensioner to allow excess play in the belt.
4. Remove bottom bolts from motor, attaching 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 slide off the motor shaft.
Motor Installation
To install the motor:
1. First, install the isolating washers and bolts into the motor mounting plate.
2. Align motor and install bolts.
3. Place key in keyway of motor shaft.
4. Fit drive pulley into belt and install onto motor shaft.
5. Center the drive pulley with the secondary pulley.
6. Apply removable thread lock to the threads of the drive pulley set screw.
7. Using 2.5mm Allen Wrench, tighten the set screw
CONTROLLER REMOVAL AND INSTALLATION
Controller Removal
1. Disconnect the Main Fuse.
2. Remove the three bolts holding the controller to the mounting plate.
3. Disconnect the two motor Field connections (F+ and F-).
4. Using a 6mm Allen Wrench, remove the three motor Armature and Ground
connections (M+, M-, and B-).

15312 200 Series 36V
Controller Installation
1. Using a 6mm Allen Wrench, connect the three motor Armature and Ground
connections (M+, M-, and B-).
2. Connect the two motor Field connections (F+ and F-).
3. Install the three bolts that hold the controller to the mounting plate.
Section 4 -DRIVE SYSTEM
Before servicing the belt or other drive components, ensure the vehicle power is
OFF and the wheels are chocked.
BELT TENSIONING AND REPLACEMENT
Belt Tensioning
Adjust both the primary and secondary belts to 1/2” flex. Do NOT over tighten,
as this will cause premature belt wear and excessive drive noise.
1. Unlock the tensioner by loosening the smaller 3/8” tensioner bolt.
2. Insert a 3/8” socket wrench into the tensioner, set to loosen (counter-
clockwise).
3. Apply a small amount of pressure to the socket wrench until there is
approximately 1/2” flex in the belt.
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 occurring.
Primary Belt Replacement
Primary belt replacement requires disassembly of the jackshaft components.
When attempting to loosen or tighten jackshaft nuts, stay clear of all belt-driven
components, as they may rotate during this process.
Before servicing, chock the rear wheels of the vehicle.
1. Remove the guard above the pulleys.
2. Loosen the primary belt tensioner by loosening the smaller 3/8” bolt.
3. Remove the nut from the left side of jackshaft
4. Slide jackshaft toward right side until the tall pulley is free to be removed.
5. Remove pulley and replace with new belt attached, starting with the belt
around the smaller drive pulley on the motor shaft.
6. Line up pulley with keyway on the jackshaft and slide the jackshaft left,
through the spacer and bearing.
Fingers or other body parts can get
severely injured by moving drive
components.

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200 Series 36V 15312
7. Install and tighten jackshaft nut until there is no horizontal play in the
pulleys (approx. 90 –110 ft-lbs).
8. Tension the belt following the instructions found in Section 4 -Belt
Tensioning.
9. Replace guard removed in step 1.
Secondary Belt Replacement
Secondary belt replacement requires disassembly of the jackshaft components.
When attempting to loosen or tighten jackshaft nuts, stay clear of all belt-driven
components, as they may rotate during this process.
1. Jack the vehicle’s swingarm and place on jack stands to keep the rear wheels
off the ground. Do NOT use the Axle as a jack point.
2. Remove left rear tire/wheel
3. Remove the guard above the pulleys.
4. Loosen the secondary belt tensioner’s smaller 3/8” bolt.
5. Loosen left rear axle bearing flange and slide bearing assembly to the left.
6. Remove the right jackshaft nut.
7. Slide the jackshaft to the left until the wide pulley is free to be removed.
8. Remove secondary 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, through the slot of the
swingarm axle bracket, and placing it over the axle pulley.
10.Place loose pulley inside the belt.
11.Line up pulley with keyway on the jackshaft and slide the jackshaft right,
through the spacer and bearing.
12.Install and tighten jackshaft nut until there is no horizontal play in the
pulleys (approx. 90 –110 ft-lbs).
13.Replace guard removed in step 3.
14.Tension the belt following the instructions found in Section 4 -Belt
Tensioning.
15.Reinstall the left rear tire/wheel.
16.Raise vehicle slightly and remove jack stands and lower vehicle.
Section 5 -THROTTLE
Proper installation and adjustment of the throttle assembly will ensure safe and
reliable control. Improper adjustment could result in undesirable results, such as a
sticking throttle pedal or lack of functionality. Follow the instructions below.
THROTTLE INSTALLATION AND ADJUSTMENT
Before working on the throttle assembly, ensure the key switch is in the OFF
position.

15312 200 Series 36V
The following instructions include replacement of the sensor, switch, and bracket.
Throttle Assembly Removal
1. Disconnect throttle sensor and safety switch.
2. Unhook the throttle spring from the throttle bracket.
3. Loosen the throttle bracket adjustment screw.
4. Remove the throttle pedal bolt.
5. Remove throttle assembly.
Throttle Sensor Removal
6. Using pliers, carefully remove the throttle sensor clip.
Throttle Safety Switch Removal
7. Remove the two nuts holding the switch in place.
Throttle Safety Switch Installation
8. Align the two holes on the safety switch with the holes in the throttle
bracket.
9. Install both mounting bolts and locking nuts.
Throttle Sensor Installation
10.Align sensor and clip with holes in throttle bracket. 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 sensor may have
some play between the bracket and clip. This is normal.
Throttle Assembly Installation
12.Install the throttle pedal bolt through the throttle components as shown
below.
13.Verify the throttle pedal is free to move and is not bound.
14.Tighten the nut for the throttle pedal bolt.
15.Again, verify the throttle pedal is free to move.
16.Connect the throttle spring, starting with the throttle pedal, then the throttle
bracket.
17.Connect the wires and connector to the sensor and switch.
18.Follow the test procedures in section Section 9 -Procedures to verify the
correct signals are at the motor controller.
19.With the seatbelt properly fastened, attempt to drive the vehicle slowly to
ensure proper functionality of the throttle circuit.

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

15312 200 Series 36V
Figure 2 Motor Controller Schematic

Page 11
200 Series 36V 15312
BATTERIES
Batteries contain acid that can be harmful. Therefore, special care must be taken
when handling.
Testing and Water Level
Each battery should measure at least 12.8V fully charged. Before charging,
ensure the water level for each cell of the batteries is at least slightly above the
plates as shown below. If any battery cannot be charged to this level, ensure
the water level is where it should be, per the instructions below. If the water
level is good and the battery(ies) still will not hold 12.8V or higher, check the
specific gravity for each cell.
1. Open the vent caps and look inside the fill wells.
2. Check electrolyte 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 adding any additional water (refer
to Raise vehicle slightly and remove jack stands and lower vehicle.
5. Charging below).
6. Once charging is completed, open the vent caps and look inside the fill wells.
7. Add water until the electrolyte level is 1/8" below the bottom of the fill well.
8. A piece of rubber can be used safely as a dipstick to help determine this
level.
9. Clean, replace, and tighten all vent caps.
Replacement
Each battery in the system should be the same make and model. Replacing a
battery with one of a different rating may hinder vehicle performance and fail
prematurely.
To remove one or more batteries:
Water level above this point
before charging.

15312 200 Series 36V
1. Jack the vehicle’s swingarm and place on jack stands to keep the rear wheels
off the ground. Do NOT use the Axle as a jack point.
2. Remove one of the rear wheel assemblies to give access to the preferred
side or removal.
3. Disconnect Main Fuse.
4. Disconnect battery wiring to all batteries.
5. Remove battery hold down nuts 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 replaced.
To install one or more batteries:
8. Slide battery into place, keeping its orientation correct, as shown here:
9. Install battery hold down.
10.Install battery hold down nuts.
11.Install wiring to batteries and Main Fuse as shown here:
12.Torque battery nuts to 8~10 ft-lbs (96~120 in-lbs).
13.Double-check all wiring, nuts, and battery orientation.

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200 Series 36V 15312
14.Connect Main Fuse.
15.Turn ON the key and check that throttle functions properly.
16.Reinstall wheel assembly.
17.Raise vehicle slightly and remove jack stands and lower vehicle.
Charging
The included onboard NOCO Genius charger is a complete charger and
maintainer package. It charges and maintains each battery individually.
Charging starts soon after the charger is plugged in. A slight spark when first
plugged in is normal.
For the first minute after the charger is plugged in, a series of checks is
performed to ensure it is safe to charge the batteries. After a minute or so,
charging begins at up to 10A per battery. From this point on, the charger
constantly monitors the battery state of charge to determine which of the 7
charging steps are most appropriate.
A red light indicates the battery is being charged. Green indicates the charger is
in the final stage of charge and is at least 90% charged. Over the next 2 hours
or so, the battery is “topped-off”. It is okay to use the vehicle once the
chargers indicators are all green. Overall, this process can take up to 12 hours.
The charger is able to detect a battery is connected all the way down to 2V. If
the battery voltage is below 2V, the charger will flash Red/Green. In this case,
another source can be used 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 for
a moment, until the charge indicator changes from flashing Red/Green to solid
Red. Remove the external source as soon as the light is solid Red.
Flashing Red/Green lights also indicates an open battery circuit between the
charger and respective battery. Check for a broken connection/wire.
Lastly, flashing Red/Green can indicate charging cannot be completed on the
respective battery. If at any point during the charge cycle a problem is detected
with the battery, charging will stop and the lights will flash Red/Green. This
includes if charging cannot complete in a 1 hour period.
If left plugged in, as a maintenance charger, the charger will check the state of
charge on the batteries every 24 hours. If detected that the battery voltage has
dropped around 20% or more, charging will start over at the finishing stages of
charge. It is recommended that the charger remain plugged in as long as the
vehicle is not in use, including winter months or in storage.
Battery Indicator
Located in the dash is a battery discharge meter. This is driven by the 12V
battery which drives the entire 12V electrical system. If a problem is suspected
with the batteries not attached to this meter, the charger should indicate this
during the charge cycle by flashing Red/Green at any point along the charge

15312 200 Series 36V
cycle. The indicator is meant to provide the condition of the “typically” lowest
charged battery in the group.
Typically, the indicator will show empty (alternating red lights) well before the
vehicle cannot fully operate. It is okay to operate the vehicle until it slows due
to low voltage, but is recommended to be charged whenever the gauge shows
empty. This will provide the best life of the batteries.
It is normal for the discharge meter to not show an increase in voltage level
until charging has completed. Battery voltage must be greater than 14.1V for a
minimum of 7 minutes for the gauge to reset. All digital battery indicators have
this characteristic to prevent the gauge from indicating 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 should also be indicating a problem on the respective battery.
Section 7 -CHASSIS
STEERING ALIGNMENT
For best off-road performance, the steering alignment should be set “toed-in” as
shown here:
The front wheel should be “toed-in”1/8” to 1/4".
To check alignment measure distance from A to B to the centerline (CL) of the tires
with the wheels point straight ahead. For the proper toe-in dimension A should be
1/8 ~1/4" greater than dimension B.
Loosen the locknuts on both sides of Front Tie Rods. To Make Dimension B smaller,
screw the rod left. If B needs to be longer screw the rod right.
Tighten the jam nut tightly against the rod end.
Recheck the distance and repeat the above steps until the Dimensions are per
paragraph 1 above.

Page 15
200 Series 36V 15312
Section 8 -BRAKES
BRAKE SYSTEM REPLACEMENT

15312 200 Series 36V
Section 9 -TROUBLESHOOTING
FLOWCHART
Follow the steps below to quickly diagnose common issues. For detailed testing
information, see Procedures below. It is strongly recommended to first check all
wiring connections and terminals to ensure that they are securely attached. Loose
connections are the most common cause for electrical issues.
Issue
Test Item
If Fail
Vehicle does not
move when
throttle depressed
Turn Key Switch ON
Having the throttle
depressed while
shifting from “F” to
“R” or visa-versa will
generate a fault.
Reset Key Switch to
resolve the fault.
Battery Gauge turns ON
Check Main Fuse
Check 12V circuit Fuse
Check Yellow Body connector
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 hot,
controller is bad. Disconnect Main
Fuse.
Check 36V circuit Fuse
Check for >36V at Purple wires at
Motor Controller
Check condition or all other connections
at controller
Turn Key Switch OFF
Throttle Switch continuity to
Ground with Throttle
depressed (white wire at
controller)
Check connections at Throttle Switch
Throttle Sensor resistance
normally below 120Ω(Gray
to Gray/Black wires at
controller)
Check that Throttle Pedal has fully
returned
Inspect Throttle sensor closely for
cracks
Throttle Sensor resistance
above 4300Ωwhen Throttle
depressed (Gray to
Gray/Black wires at
controller)
Check condition of connections at
Throttle Sensor
Check connection to harness

Page 17
200 Series 36V 15312
Vehicle will not go
in Reverse
Turn Key Switch OFF
Connections at F/R Switch
are good

F/R Switch continuity while
“R” is selected (Blue to
Blue/Yellow wires at
controller)
Check connections at controller
PROCEDURES
Throttle Harness: Throttle Sensor / Potentiometer Signal
Confirm that the throttle position sensor signal is making it to the controller.
Remove the 5-pin connector from the controller. There will be three wires in it.
Use “Ω” 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 be less than 160
Ohms (Ω).
Depress plunger by pressing down on the throttle pedal. With the throttle fully
depressed, the resistance should be at least 4,300 Ohms (Ω) or 4.3KΩ.
If this test result is good, the throttle position sensor is also good and does not need
tested as an individual component.
Throttle Harness: Throttle Switch Signal
Confirm that the throttle switch signal is making it to the controller.
Throttle Harness
Throttle Harness
Controller