Re: Whats the craziest mech. issue you ever had?

Posted by wisbaker on July 01, 2014 at 20:50:17 from (173.30.33.15):

In Reply to: Whats the craziest mech. issue you ever had? posted by Fullers Farmalls on July 01, 2014 at 19:08:26:

Probably the most frustrating, when at the golf course we got our first new Cushman in years, the previous administration bought Toro Workmasters (slow) and EZ-GOs (better than Workmasters, but not great). After about a year we got another one, about 3 months later the first one starts acting up, almost like it's running out of fuel, I go through the fuel system time and time again...nothing, then the 2nd one starts acting up same thing, but it's still under warranty so we ship it back to the dealer. So now we're down 2 carts on a fleet of 5, 2 weeks later we get the 2nd Cushman back. Seems they mis-assembled it at the factory and put the left head on the right side and the right head on the left side. The problem is that exhaust valves became intake valves (not a problem) so the intake valves became exhaust valves (and they couldn't take the heat and burned)reducing the suction of the intake stroke.

The one that made me feel the most stupid, the EZ-Go got to be hard to start, it didn't want to turn over and the gauges went all funky anytime you tried to start it. Battery voltage was good, the alternator charged and if you jumped it it would spin over like it should. While trouble shooting it I had the dashboard open tried starting it , no go, went to move some wires and burnt my hand on the speedometer cable. Finally figured it out, the battery was grounded to the frame and there was another cable that jumpered from the frame to the engine/transmission, that cable was mostly broken, the speedometer cable got hot because it was trying to ground through it, the starter pulled more amps than the speedo cable was good for so it would get a little hot.

The one that kicked my backside was at one of the rendering plants. The presses started falling down. About the time they got the evaporators fully opened up the meal out of the presses would get wet and they'd have to slow down. It seemed to get worse every two to three weeks and they'd have to run slower and slower. Our instrument guys went through all the instruments insuring everything was calibrated, and still it got worse. Eventually my boss figured it out. Our operations director was trying to reduce the residual fat in our meal. He went to the guy we had building the press cages and gave him a box of thinner spacers and told him to start using them. Well with the thinner spacers it required an extra press bar to get the cages tight, this also means the inside diameter of the press cage was a little bigger, increasing the clearance between the cage and shaft. The increased clearance wasn't allowing the press to build enough pressure to send the fat out between the slats and dry meal out through the choke head. It got worse every two or three weeks because that's when another press timed out and we would change it out with a new shaft and "improved" cage. Oh the operations director was the company president's brother.

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