Controller Replacement; Solenoid Replacement - Cushman SHUTTLE 4X Technician's Repair And Service Manual

Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

CONTROLLER REPLACEMENT

Tool List
Socket, 3/8" ................................................................. 1
Socket, 7/16" ............................................................... 1
Socket, 1/2" ................................................................. 1
Socket, 1/4" ................................................................. 1
Ratchet ........................................................................ 1
Extension, 6" ............................................................... 1
Insulated wrench, 9/16"............................................... 1
Shop towel................................................................... 1
Torque wrench, in. lbs. ................................................ 1
Torque wrench, ft. lbs. ................................................. 1
Large Screwdriver ....................................................... 1
Remove the seat.
Before any electrical service is performed on TCT model
vehicles, the Run-Tow/Maintenance switch must be
placed in the 'Tow/Maintenance' position.
If a power wire (battery, motor or controller) is disconnect-
ed for any reason on the TCT model vehicle, the Run-
Tow/Maintenance switch must be left in the 'Tow/Mainte-
nance' 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.
Note the location of the wiring on the controller before remov-
ing wiring from controller (Ref. Fig. 8 on Page F-8).
Using an insulated wrench, remove the BL- wire from
the battery.
Remove the environmental cover.
Remove the controller mounting bolts and remove the
.
controller
Mount new controller and reconnect wiring. Tighten the
controller mounting bolts to 132 - 168 in. lbs. (15 - 19
Nm) torque and the terminal bolts to 120 - 144 in. lbs.
(13.5 - 16.3 Nm) torque.
Replace the environmental cover and tighten the mount-
ing bolts to 35 - 44 in. lbs. (4 - 5 Nm) torque.
Reconnect the BL- battery cable and replace the seat.
ELECTRONIC SPEED CONTROL - TCT

SOLENOID REPLACEMENT

Qty.
Tool List
Socket, 3/8" .................................................................1
Socket, 7/16" ...............................................................1
Socket, 1/2" .................................................................1
Socket, 5/16" ...............................................................1
Ratchet ........................................................................1
Extension, 6"................................................................1
Insulated wrench, 9/16" ...............................................1
Shop towel ...................................................................1
Torque wrench, in. lbs..................................................1
Torque wrench, ft. lbs...................................................1
Large Screwdriver........................................................1
Remove the seat.
Before any electrical service is performed on TCT model
vehicles, the Run-Tow/Maintenance switch must be
placed in the 'Tow/Maintenance' position.
If a power wire (battery, motor or controller) is disconnect-
ed for any reason on the TCT model vehicle, the Run-
Tow/Maintenance switch must be left in the 'Tow/Mainte-
nance' 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.
Note the location of the wiring on the solenoid before removing
wiring from solenoid (Ref. Fig. 13 on Page F-14)
Using an insulated wrench, remove the BL- wire from
the battery.
Remove the environmental cover.
Remove the solenoid mounting bolts and remove the
solenoid
Mount new solenoid and reconnect wiring. Tighten the
solenoid mounting nuts to 45 - 55 in. lbs. (5.1 - 6.2 Nm)
torque, the #10 terminal nuts to 15 - 20 in. lbs. (1.7 - 2.3
Nm) and the 5/16" terminal nuts to 44 - 50.4 in. lbs (5 -
5.7 Nm) torque.
Replace the environmental cover and tighten the mount-
ing bolts to 35 - 44 in. lbs. (4 - 5 Nm) torque.
Repair and Service Manual
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B
B
Qty.
Page F-13