Circuits And Controls; Starter; Generator; Wiring - Cushman HAULER 800X 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.

CIRCUITS AND CONTROLS

The electrical system is a 12 volt negative ground sys-
tem (Ref. Fig. 1) (Ref. Fig. 2) consisting of a:
• battery
• starter/generator
• voltage regulator
• solenoid
• magneto
• fuse
• key switch
To prevent injury or death from inadvertent
movement of vehicle, all tests performed
requiring starter/generator or engine to rotate
must be performed with the rear wheels raised
(see Section "B") or the neutral lock engaged
(see Section "A").
Follow the lifting procedure in Section "B" of
this manual. Place wheel chocks in front of and
behind the front wheels. Check the stability of
the vehicle on the jack stands before starting
any repair procedure. Never work on a vehicle
that is supported by a jack alone.

STARTER

When starting the engine, the field coils are in series
with the armature and the starter/generator operates as
a motor (Ref. Fig. 1).This circuit is controlled by a key
switch, fuse, accelerator limit switch and a solenoid.
With the key in the 'ON' position, battery current is avail-
able to the accelerator limit switch which remains open
until the accelerator pedal is pressed. When the pedal is
pressed, the plunger on the switch is released, the con-
tacts close and the ignition circuit is energized. Battery
current then energizes the solenoid which closes the
contacts and energizes the starter circuit. The starter/
generator now functions as a starter to start the engine.

GENERATOR

When the engine is running, the starter/generator func-
tions as a generator. This is used for charging the bat-
tery and for the ignition system. Generated output is
controlled by the voltage regulator at 14.25 - 14.75 V,
without regard to engine speed. However, the charging
current will vary depending on the condition of the bat-
tery. If it is fully charged, current is controlled at 3 to 5
amps.

WIRING

Before performing any test of wiring compo-
nents, disconnect the battery cables from the
battery posts to prevent electrical shock or
explosion (see procedure in Section "B").
Electrical tests of the wiring for continuity may be made
with a DVOM (Digital Volt Ohm Meter) available through
the Service Parts Department (P/N 27481-G01). Any
DVOM may be used, however the controls, displays and
features may vary depending on the make and model.
Set the meter selector to the ohms scale and check con-
tinuity between each circuit component as indicated.
Example: If a switch is open or if there is a break in the
wiring, the meter will display a visual signal. If an analog
meter is used it will read infinity (

TESTING IGNITION CIRCUIT

This section assumes the fuel system is functioning and that
the engine is receiving fuel.
Tool List
Dvom ...........................................................................1
Spark plug (NGK BPR2ES) .........................................1
Spark plug tester..........................................................1
To prevent possibility of personal injury, never
operate the starter unless both spark plugs are
installed or the ignition system is disabled.
Fuel drawn into the cylinders will be expelled
through the spark plug opening and could be
ignited by the ignition system or another
source, resulting in a fire.
The engine incorporates a magneto type ignition sys-
tem. There is no distributor.
The engine can be stopped by turning the key switch to
the 'OFF' position. When the accelerator pedal is
released, the limit switch contacts open and the ignition
circuit is de-energized.
Repair and Service Manual
ELECTRICAL
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NOTICE
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