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Maintenance ManualBUMPER CARS TABLE OF CONTENTS
2.0 OPERATING PROCEDURES 3.0 MAINTENANCE PROCEDURES 3.1 Internal Components 3.1.1 Batteries 3.1.2 Drive Chains 3.1.3 Motor 3.1.4 Load Wheels 3.1.5 Swivel Caster Wheels 3.1.6 Nuts and Bolts 3.1.7 Electrical 3.2 External Components 3.2.1 Battery Charger 3.2.2 Bumper Car Tube 3.2.3 Master Power Switch (the red button) 3.2.4 Remote Control 3.2.5 Joysticks 3.3 Maintenance Schedule 4.0 PHYSICAL LIMITATIONS (for the rider’s safety) 5.0 WIRING SCHEMATIC 6.0 BUMPER CAR LIMITED WARRANTY 7.0 TROUBLESHOOTING GUIDE 8.0 ASSEMBLY DRAWINGS - Bumper Car Manual v2.3
Bumper Cars 1.0 OVERVIEW
The bumper car experience allows individuals to drive around in their independently operated bumper car and safely collide with other individuals with a similar vehicle. The bumper cars have a very low center of gravity, which eliminates any possibility of tipping over. But as a safety precaution, there are lap belts to secure the driver in their seat. The bumper cars are a motorized vehicle in which each drive wheel (2) has its own motor and joystick. These enable the driver to make sharp turns, circles, forward as well as reverse capabilities. The bumper cars are circular in shape and protected by a circular tube of air. This bumper cushion absorbs most of the shock, resulting in very low “G” forces even when driven by the most aggressive rider. The bumper cars come with a hand held remote control transmitter that the operator uses to control all the bumper cars’ ability to move. To maintain a bumper car’s optimal performance, the following operation, physical limitations, and maintenance should be followed.
2.1 Turning a bumper car on
2.1.1 Turn bumper car’s power on Twist the master power switch to the ON position.
2.1.2 Engage Remote Push the blue button on the remote to enable the bumper car to move-this could take more than one push of the blue button. To check that the bumper car can move freely, move one of the joysticks.
2.1.3 The bumper car is ready for operation.
2.2 Turning a Bumper car off / emergency stop 2.2.1 For normal on/off operation push the blue and red buttons on the remote to start and stop the bumper car. 2.2.2 For emergency stop and end of day storage, push the master power switch button in to turn the bumper car’s power off. - Bumper Car Manual v2.3
3.0 MAINTENANCE PROCEDURES
3.1 Internal Components
3.1.1 Batteries There are two 12VDC, 75 Amp Sealed Gel-Cell batteries per bumper car. Since these are sealed batteries they require no maintenance. A battery should be replaced if it does not hold a charge. Removal Procedures: 1) Turn Master Power Switch off (push button in). 2) Remove the negative and positive cables from the battery. 3) Remove the wing nuts & cross bar that hold the batteries in place. 4) Lift battery up and remove from the bumper car.
During regular maintenance the drive chains must be lubricated and tightened. Make sure the chains are tightened to a tension of ½ inch of slack at the chain's tightest point. The chains must be removed if the chain is too long and needs to be shortened or if the chain is damaged and needs to be replaced.
Tightening chain: 1) Turn Master Battery Disconnect switch off (push button in). What is the Master Battery Disconnect switch? 2) First check the tension between the drive wheel and the gear bracket. If the chain is a little too lose or a little too tight adjust the gear shaft tension rod (see Bear Bracket photo). Loosen the rod tension nut to the left (lengthen the rod) to decrease the tension in the chain. Rotate the tension nut to the right (shortening the rod) to increase the tension in the chain.
3) Second check the tension between the gear shaft and the motor. If the chain is a little too lose or a little too tight adjust the tension rod (See the above motor photo). Loosen the jam nut and rotate the tension bolt to the right (shortening the rod) to increase the tension in the chain. Rotate the tension bolt to the left (lengthen the rod) to decrease the tension in the chain. 4) Excessively lose or tight. If the chain is still to lose or tight after adjusting the tension rods then the chain must be removed so chain links can either be removed or added.
Removal Procedures: 1) Turn Master Battery Disconnect switch off (push button in). What is the Master Battery Disconnect switch? 2) Find the master link on the chain. Remove the master link and the chain will remove-similar to a bicycle chain.
Each bumper car comes with two motors. Each motor drives a load wheel through a chain drive system and the joystick controls the direction of the motor’s rotation.
Motors maintenance will include replacing worn motor brushes. Signs that the brushes need replacement are loss of power and the inability to drive in a straight line. It is highly recommended that all 4 motor brushes (2 per motor) be replaced at the same time.
To check motor brushes unscrew the caps at the rear of the motor.
If the motor needs to be removed for repairs or replacement the following procedures apply.
Removal Procedures 1) Turn Master Battery Disconnect switch off (push button in). What is the Master Battery Disconnect switch? 2) Remove the chain system that the motor is connected to. 3) Remove the gear bracket by unbolting the two bolts that are holding it in place (one on each side of the bracket). Remove the tension rod. By doing this the gear will release. 4) Remove the bolt holding down the motor. 5) Remove the motor.
Each bumper car has two 2-½ inches X 10 inches wheels with roller bearings. These wheels need to be greased during a bumper car’s regular maintenance. If the wheels are cracked or damaged in such a way that they do not turn correctly they must be replaced.
Removal Procedure: 1) Turn Master Battery Disconnect switch off (push button in). What is the Master Battery Disconnect switch? 2) Each load wheel has 2 collar shafts, one on each side of the wheel; these are locked into place by screws. In order to remove the wheel these 2 shaft collars must be removed by removing the screw that locks them into place.
Screws that hold the collar shaft in place
Each bumper car has two swivel casters located in the front and the back of the bumper car. The bumper car is designed so both of the swivel casters do not touch the ground at the same time. As the load wheels wear down both of the swivel casters will eventually touch the ground at the same time. If both of the swivel casters touch the ground at the same time they will prohibit the bumper car from moving, the load wheels will not be able to work properly. Therefore, it is important to replace the load wheel when both casters touch the ground at the same time (so the bumper car will function properly)! The swivel caster wheel is 1 ½ inch wide X 2-½ inch diameter. If the swivel casters do not swivel or spin properly they must be replaced.
Removal Procedure: 1) Turn Master Battery Disconnect switch off (push button in). 2) Lift the bumper car up off the ground and secure it so it will not fall or move during the removal of the swivel caster wheel(s).
3) Unbolt the 4 bolts holding the swivel caster assembly in place and the swivel caster will remove.
Because a bumper car experiences lots of vibrations during usage all the nuts and bolts of a bumper car need to be checked during regular maintenance.
A bumper car’s electrical cords and connections should be checked during regular maintenance. 1) The electrical connections should be secure-not loose. 2) The electrical wires should be completely covered by a protective, insulating external layer. If the electrical wires are not completely covered they must be replace immediately.
3.2 External Components
The charger comes with a cord that connects to the bumper car’s charging plug.
Each bumper car comes with one bumper car tube. The bumper car tube pressure must be 2 pounds per square inch (10.3-13.8 KPa) at room temperature do not exceed 3 psi (20.7 KPa). If a tube has any small holes or scratches they can be patched.
Removal Procedure if the bumper car tube needs to be removed from the bumper car for repair or replacement: 1) Turn Master Battery Disconnect switch off (push button in). What is the Master Battery Disconnect switch? 2) Deflate the tube by twisting off the valve cap and releasing the air inside, this is similar to deflating a bicycle tire. Once the tube is completely deflated pull all the slack to the back and proceed to lift it up and over the body until it is completely removed.
3.2.3 Master Battery Disconnect (the red button)
The Master Battery Disconnect button is located next to the driver’s headrest of the bumper car. When the button is twisted it springs out the bumper car’s power is turned on. When the button is pushed in the bumper car’s power is turned off. When the bumper cars are not in use, always keep the master battery disconnect button in the off position. This button can also serve as an emergency stop button.
One remote control controls all the bumper cars, but before the remote can function properly the master battery disconnect button must be in the on position (pulled out). When there is power in the bumper car the remote can control the bumper car to stand-by or running mode. Push the blue button on the remote to enable the bumper cars to move (running mode) and push the red button on the remote to stop the bumper cars from moving (stand-by mode).
Each bumper car has two joysticks; each joystick controls one of the drive wheels. If the joystick is pushed forward the load wheel moves forward. If the joystick is pulled backward then the wheel moves backward. If the joystick is not responding make sure: - The Master Battery Disconnect switch is in the on position (pulled out). - The remote activated the bumper car’s mobility - All the electrical connections are tight, secure, and functioning properly - There is electricity flowing from the control to the joystick, which can be checked with a voltmeter. If there is no electricity flowing from the control box, then check if there is electricity flowing from the batteries to the control box. If there is power to the control box then the control box must be repaired or replaced. If there is no power to the control box the batteries must be charged or replaced.
If the joystick still does not respond replace the joystick.
Removal Procedures: 1) Make sure the Master Battery Disconnect switch is in the off position (pushed in). 2) Unscrew and remove the cover over the joystick. 3) Remove the 4 cables from the joystick. 4) Unbolt the 4 bolts securing the joystick assembly to the bumper car’s body. 5) Remove the joystick assembly.
3.3 Maintenance Schedule Bumper Cars
Per Mfg’s Manual = Refer to the manufacturer’s manual.
There is no height limitation other than ensuring that the individual can reach the joysticks and be held securely by the lap restraint system. 4.2 Weight Limitations There is no weight restriction other than ensuring that the individual can be held securely by the lap restraint system.
Due to the excitement, forces, and motion of the bumper cars, a person must be in good health, free from heart conditions, nervous disorders, motion sickness, weak back, or any other physical limitations, including pregnancy, which would impair the use of the restraint system
6.0 BUMPER CAR LIMITED WARRANTY
The Bumper Car is warranted as to workmanship and materials for a period as set below commencing from the date of delivery. This warranty shall be limited to replacement of any defective part, F.O.B. factory, upon the return of the alleged defective part and determination by manufacturer that a part is, in fact, defective. Specifically excluded from the warranty will be any and all damage from any cause other than improper workmanship or defective materials, as well as any consequential damages of any nature. Parts Covered by this Warranty; Length of Warranty: • Bumper car frame and fiberglass excluding appearance-related damage(scratches, nicks dents fading, paint/trim, and corrosion) is 1 year from the sale to the end-user. • Bumper Car Tubes is 90 days from the sale to the end-user.• Parts and accessories is 90 days from the sale to the end-user. Warranty excludesnormal wear and tear to joysticks, phenolic wheels, and casters. All parts replaced under warranty will be considered as part of the original product and any warranty of those parts will expire concurrent with the original product warranty. Any responsibility for loss of time or use of the product, transportation, commercial loss or any other incidental or consequential damage is disclaimed. These warranties are in lieu of all other warranties, whether expressed or implied, including implied warranties of fitness for use and merchantability, except as specifically set forth in this agreement, and do not apply with respect to any defects or unsuitability which are attributable to repair, alteration, misuse, or abuse by any person other than manufacturer.
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