Cushman HAULER 800 2012 Technician's Repair And Service Manual page 98

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.
B
CONTROLLER REPLACEMENT
Tool List
Socket, 10mm, 3/8" drive ............................................ 1
Socket, 7/16", 3/8" drive .............................................. 1
Socket, 13mm, 3/8" drive ............................................ 1
Ratchet, 3/8" drive ....................................................... 1
Extension, 6", 3/8" drive .............................................. 1
Insulated wrench, 9/16" ............................................... 1
Shop towel................................................................... 1
Torque wrench, 3/8" drive, in. lbs. ............................... 1
Torque wrench, 3/8" drive, ft. lbs. ................................ 1
Remove the seat.
Before any electrical service is performed on 48 volt mod-
el vehicles, the Run-Tow/Maintenance switch must be
placed in the 'Tow/Maintenance' position.
If a power wire (battery, motor or controller) is discon-
nected for any reason on the 48 volt model vehicle, the
Run-Tow/Maintenance switch must be left in the 'Tow/
Maintenance' position for at least 30 seconds after the
circuit is restored.
To prevent electrical shock, the BL- wire must
be removed before discharging the controller
by shorting the B+ and B- terminals of the con-
troller with a large screwdriver. Be sure to hold
screwdriver by the insulated portion.
Using an insulated wrench, remove the BL- wire from
the battery.
Note the location of the wiring on the controller before remov-
ing wiring from controller. (Ref. Fig. 30 on Page F-33)
Remove the controller mounting nuts and remove the
.
controller
Mount new controller to mount and reconnect wiring.
Tighten the controller mounting bolts to 108 - 132 in. lbs.
(12 - 15 Nm) torque and the M6 (F1 and F2) bolts to 80 -
90 in. lbs. (9 - 10 Nm) torque and M8 (B+, M-, B-) bolts
to 120 - 130 in. lbs. (14 - 15 Nm) torque.
Replace controller mount assembly in vehicle. Replace
and tighten nuts to 6 - 8 ft. lbs. (8 - 11 Nm) torque.
Reconnect the BL- battery cable and replace the seat.
Page F-32
NOTICE
Repair and Service Manual
SOLENOID REPLACEMENT
Qty. Tool List
Socket, 3/8", 3/8" drive ................................................1
Socket, 7/16", 3/8" drive ..............................................1
Socket, 1/2", 3/8" drive ................................................1
Ratchet, 3/8" drive .......................................................1
Extension, 6", 3/8" drive...............................................1
Insulated wrench, 9/16" ...............................................1
Shop towel ...................................................................1
Torque wrench, 3/8" drive, in. lbs.................................1
Remove the seat.
Before any electrical service is performed on 48 volt mod-
el vehicles, the Run-Tow/Maintenance switch must be
placed in the 'Tow/Maintenance' position.
If a power wire (battery, motor or controller) is discon-
nected for any reason on the 48 volt model vehicle, the
Run-Tow/Maintenance switch must be left in the 'Tow/
Maintenance' position for at least 30 seconds after the
circuit is restored.
To prevent electrical shock, the BL- wire must
be removed before discharging the controller
by shorting the B+ and B- terminals of the con-
troller with a large screwdriver. Be sure to hold
screwdriver by the insulated portion.
Using an insulated wrench, remove the BL- wire from
the battery.
Note the location of the wiring on the solenoid before removing
wiring from solenoid (Ref. Fig. 30 on Page F-33)
Remove the solenoid mounting bolts and remove the
.
solenoid
Mount new solenoid and reconnect wiring. Tighten the
solenoid mounting nuts to 67 - 82 in. lbs. (8 - 9 Nm)
torque, the #10 terminal nuts to 13 - 17 in. lbs. (1 - 2 Nm)
and the 5/16" terminal nuts to 50 - 60 in. lbs (6 - 7 Nm)
torque.
Reconnect the BL- battery cable and replace the seat.
NOTICE
Qty.