Cushman HAULER 800 2012 Technician's Repair And Service Manual page 85

ELECTRONIC SPEED CONTROL - HAULER 1000
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings.
Fig. 16 Controller and Solenoid
The pedal box is connected to the controller through a
24-pin plug at J1 on the controller. The speed sensor is
connected to the controller through a three-pin plug at
J2 (Ref. Fig. 21 on Page F-23).
The controller is wired to the batteries and develops a
regulated power supply for the ITS. The plunger position
relative to the ITS varies the voltage which is fed back to
the controller which interprets the change in voltage and
supplies the appropriate power to the motor.
The ITS unit and the controller are both solid state units
that contain no user serviceable parts. The testing pro-
cedures are designed to test the basic functionality
of the power and control wiring systems. Once the
functionality of the wiring has been confirmed, the
remaining tests are used to identify which of the compo-
nents (controller or ITS) must be replaced.
F2
B+
J3
J2
M-
J1
B-
F1
Repair and Service Manual
GENERAL TROUBLESHOOTING
Tool List
Floor jack .....................................................................1
Jack stands..................................................................2
Wheel chocks ..............................................................4
Jumper wire (with alligator clips)..................................1
DVOM ..........................................................................1
Socket, 3/8", 3/8" drive ................................................1
Ratchet, 3/8" drive .......................................................1
Torque wrench, in. lbs., 3/8" drive................................1
Torque wrench, ft. lbs., 3/8" drive.................................1
Extension, 6", 3/8" drive...............................................1
Insulated wrench, 9/16" ...............................................1
Wrench, 1/2" ................................................................1
Wrench, 7/16" ..............................................................1
Phillips screwdriver, large ............................................1
Phillips screwdriver, small............................................1
Shop towel ...................................................................1
Allen wrench,.050" .......................................................1
Drill bit, 7/32"................................................................1
Symptoms
Vehicle does not operate, operates poorly or intermit-
tently.
Testing
A maintenance feature of the 48 volt controller is the
ability to diagnose electrical faults preventing the vehicle
to operate at its fullest potential. A light on the controller
face will blink informing the technician to the cause of
the vehicle malfunction.
A series of blinks will indicate the fault code (one, two,
three, four or five followed by a pause and one, two,
three, four or five more blinks). By reading the decal
attached near the controller, or by reading the 48 volt
Diagnostic Mode Fault Code chart (Ref. Fig. 20 on Page
F-22), the fault, its symptom(s) and corrective action to
be taken can be found.
It is unlikely that the mechanical adjustment of the pedal
box has changed, therefore the initial tests will be con-
ducted with a digital volt ohm meter (DVOM) to identify
the failed component.
A typical DVOM is shown in illustrations. A recom-
mended DVOM is available through the E-Z-GO Service
Parts Department as P/N 27481-G01. Any DVOM may
be used; however, the accuracy, controls, displays and
features may vary depending on the make and model.
Always follow the meter manufacturer's recommenda-
tions and instructions for the use and care of the meter.
B
B
Qty.
Page F-19