Pedal Box; Speed Sensor; Controller; General Troubleshooting - Cushman HAULER 800 2012 Technician's Repair And Service Manual

ELECTRONIC SPEED CONTROL - HAULER 800 - TCT
Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
Hill option will slow the vehicle to a stop at a slower rate
unless the accelerator pedal is depressed.
The TCT has a low power consumption unit but it will
drain the vehicle batteries over a period of time. If the
vehicle is to be stored for a prolonged period of time, the
TCT should be disconnected from the batteries by
selecting the 'TOW/MAINTENANCE' position on the
Run-Tow/Maintenance switch located under the passen-
ger seat.
The Electronic Speed Control system consists of three
separate units; a pedal box, speed sensor, and control-
ler.

Pedal Box

The pedal box assembly is a modularized unit that con-
tains the accelerator pedal, return spring and an
enclosed box that contains the pedal position micro
switch and a solid state Inductive Throttle Sensor (ITS)
that is activated by a moving plunger attached to the
accelerator pedal. To access the pedal box, remove the
rocker panel, lift the floor mat, and remove the access
cover from the floor (Ref. Fig. 3 on Page F-3). The ITS
and plunger are accessed by removing the two screws
and top cover from the enclosed pedal box.
Rocker Panel
Fig. 2 Access to Pedal Box

Speed Sensor

The speed sensor uses a sealed sensor to read the
impulses of a ring magnet attached to the armature shaft
of the motor. Magnetic pulses are converted into electri-
cal signals which the controller uses to determine the
motor speed.

Controller

The controller is a solid state unit that activates a sole-
noid and controls the function of the vehicle by respond-
ing to inputs from the ITS, motor speed sensor and
Access Cover
Floor Mat
Pedal Box
Repair and Service Manual
many other units. The controller and solenoid are
located under the seat on the passenger side of the
vehicle (Ref. Fig. 3 on Page F-3).
Fig. 3 Controller and Solenoid
The main wire harness, pedal box, and speed sensor
are connected to the controller through a 16 pin plug
(Ref. Fig. 8 on Page F-8). The pedal box is connected to
the controller through a four pin plug on main wire har-
ness. The speed sensor is connected to the controller
through a three pin plug on main wire harness.
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.

GENERAL TROUBLESHOOTING

Tool List
Floor jack .....................................................................1
Jack stands..................................................................2
Wheel chocks ..............................................................4
Jumper wire (with alligator clips)..................................1
B
B
Qty.
Page F-3