Body - Cushman TITAN LD 36V Service & Parts Manual

BODY

Failure to follow this warning can cause severe
personal injury or death.
This vehicle is designed and constructed for OFF-ROAD USE ONLY.
Do not use this vehicle on any public roadway where automobiles
or other motor vehicles are present. Such use can be hazardous to
the operator and other drivers, passengers or bystanders.
NOTICE
THIS VEHICLE IS EQUIPPED WITH A
THROTTLE-SOLENOID INTERLOCK SYSTEM.
IN CASE OF POWER INTERRUPTION,
RELEASE AND REAPPLY THROTTLE.
(SEE OWNER'S MANUAL) 825394
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22
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Page C-1
FIRE DAMAGE MAY OCCUR TO WIRES
AND ELECTRICAL COMPONENTS IF
VEHICLE IS TOWED. REMOVE MOTOR
LEAD CONNECTIONS IF VEHICLE IS
TO BE TOWED.
29165G01
15
14
21
OFF
ON
600945
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7
8
5
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635593 Service Parts Manual
CAUTION
4115473
WARNING
FAILURE TO HEED THESE WARNINGS MAY RESULT IN PERSONAL
OR FATAL INJURY TO YOU OR OTHERS AND MAY ALSO RESULT
IN EQUIPMENT AND/OR PROPERTY DAMAGES.
READ, STUDY AND UNDERSTAND ALL WARNING LABELS AND OPERATING
INSTRUCTIONS FURNISHED WITH THIS EQUIPMENT PRIOR TO USE. IF ANY
PART OF THIS MATERIAL IS UNCLEAR, CONTACT YOUR FACTORY REPRE-
SENTATIVE FOR CLARIFICATION. NEVER ALLOW UNSKILLED OR IMPROPERLY
TRAINED PERSONNEL TO OPERATE THIS EQUIPMENT.
BEFORE OPERATING VEHICLE
DO NOT MODIFY OR ADD TO VEHICLE WITHOUT MANUFACTURER'S AUTHORIZATION.
CHECK VEHICLE CONDITION-DO NOT OPERATE IF MAINTENANCE OR REAPIRS ARE NEEDED.
UNDERSTAND CONTROLS AND CHECK FUNCTIONS. KEEP CONTROLS FREE OF OBSTRUCTIONS.
ALL PASSENGERS MUST BE SEATEDD IN MANUFACTURER'S APPROVED SEATS. DO NOT OPERATE
IN EXPLOSIVE OR COMBUSTIBLE ATMOSPHERE-SWITCHES SPART. CARGO MUST BE SECURED
TO PLATFORM/
WHILE OPERATING VEHICLE
KEEP BODY PARTS INSIDE VEHICLE. STAY IN SEAT, USE HAND HOLDS. AVOID SUDDEN
STARTS, STOPS, TURNS, AND DIRECTION CHANGES TO AVOID UNSEATING PASSENGERS
OR CAUSING UNSTABLE CONDITIONS. REVERSE SPEED IS EQUAL TO FORWARD SPEED ON
ELECTRIC POWERED VEHICLE. VEHICLE WITH PROGRAMMAMBLE CONTROLLELR MAY HAVE SLOWER
REVERSE SPEED. ADJUST OPERATION TO CONDITIONS OF CROUND, SPEED, LOAD, GRADES. ETC.
MAINTAIN A SAFE DISTANCE FROM PEDESTRIANS, RAMP EDGES, PLATFORMS, ETC.
OBSERVE ALL TRAFFIC REGULATIONS. OPERATE VEHICLE IN A RESPONSIBLE MANNER.
BEFORE LEAVING VEHICLE
SET DIRECTIONS SELECTOR IN "NEUTRAL". TURN KEY TO VERTICAL "OFF" POSITION
AND REMOVE. IF MALFUNCTION OCCURS, OR ADJUSTMENT IS NEEDED, HAVE ALL WORK
PERFORMED BY AUTHORIZED PERSONNEL. BLOCK WHEEELS IF PARKED ON INCLINE.
APPLY HAND PARKING BRAKE-PARKING BRAKE NOT AUTOMATICALLY SET.
IT IS YOUR RESPONSIBILITY TO KEEP ALL LABELS (DECALS) AND INSTRUCTIONAL
LITERATURE LEGIBLE AND INTACT. REPLACEMENT LABELS (DECALS) AND LITERATURE
ARE AVAILABLE FROM THE FACTORY. 827664
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WARNING
READ OPERATOR'S MANUAL BEFORE
OPERATING CHARGER.
DO NOT CHARGE IN EXPLOSIVE ATMOSPHERE.
DO NOT OPERATE VEHICLE WHILE CHARGING.
SPARKS MAY IGNITE BATTERY GAS
(HYDROGEN).
TO PREVENT ELECTRICAL SHOCK, DO NOT
USE 2-PRONG ADAPTORS.
REPLACE DAMAGED CHARGER CORDS AND
WIRES IMMEDIATELY.
OPERATIN INSTRUCTIONS
CONNECT CHARGER PLUG TO A GROUNDED
RECEPTICLE WITH POWER RATING AS
INDICATED ON CHARGER.
CHARGER WILL TURN ON AUTOMATICALLY.
Code Fault Code Symptoms
AMMMETER SHOWS WHEN CHARGER IS
1-1 HW FAILSAFE Vehicle will not run
OPERATING.
1-2 THROTTLE FAULT 1 Vehicle will not run
CHARGER SHUTS OFF AUTOMATICALLY.
1-3 SPEED SENSOR FAULT Vehicle runs slowly
KEEP CHARGER VENTILATION OPENINGS 1-4 HPD Vehicle will not run
CLEAR. POOR VENTILATION CAN DAMAGE
1-5 MOTOR STALL Vehicle stopped
CHARGER.
2-1 LOW BATTERY VOLTAGE Vehicle performance reduced
Regen performance reduced
2-2 OVERVOLTAGE
BATTERIES CHARGED IN UNHEATED AREAS
Vehicle performance reduced
2-3 THERMAL CUTBACK
(BELOW 65° F) SHOULD BE CHARGED AS 2-4 MAIN DRIVER ON Vehicle runs slowly
2-5 WALKAWAY RELAY FAULT Vehicle will not run
SOON AFTER USE AS POSSSIBLE. CHARGE
3-1 MAIN DRIVER OFF Solenoid does not close
BATTERIES ONCE EACH WEEK FOR FOUR
Vehicle runs slowly
3-2 MAIN WELDED
HOURS IN TEMPERATURE ABOVE 65° F TO
3-3 PRECHARGE FAULT Vehicle will not run
IMPROVE STATE OF CHARGE AND BATTERY
LIFE. Solenoid closes, vehicle will
3-4 FIELD MISSING
not run
3-5 WALKAWAY RELAY DRIVER Vehicle will not run
OFF
4-1 CURRENT SENSE FAULT Vehicle will not run
4-2 DRIVER OVERCURRENT Vehicle will not run
4-3 M- FAULT Vehicle will not run
4-4 WALKAWAY RELAY DNC Vehicle will not run
4-5 WELDED WALKWAY RELAY Vehicle runs slowly
Vehicle will not run
5-2 MAIN COIL OPEN
5-3 WALKAWAY RELAY DRIVER Vehicle will not run
ON
2
5-4 BLOWN FUSE Vehicle will not run
Vehicle stops
5-5 MAIN DROPOUT
Abbreviations: AUX (Auxiliary), CONT (Contactor, Solenoid), DNC (Did Not Close),
HPD (High Pedal Disable), HW (Hardware), ITS (Inductive Throttle Sensor),
1
M- (Connection at Controller), VDC (Volts Direct Current), VDD (Power Supply Fault)
DIAGNOSTIC FAULT CODES
The LED will flash a diagnostic fault code when a fault is detected
Some faults may only be detected by operating the vehicle with the rear of the
vehicle raised and supported on safety stands
Always turn the 'RUN TOW/MAINTENANCE' switch (located in the battery
compartment) to the 'TOW/MAINTENANCE' position before performing any repairs
or maintenance to the vehicle
Select 'RUN' before returning the vehicle to service
18
For LD Only
Corrective Action
Check motor wiring, replace controller
Check pedal box adjustment, connections,
replace ITS
Check speed sensor connection, and wiring,
replace sensor if required
Release and reapply pedal.
Check pedal box, linkage, switch and key switch
Remove mechanical blockage
Charge batteries, replace bad batteries
Check that battery voltage is less than 60 VDC
Allow controller to cool
Solenoid driver defective, replace controller
Walkaway relay coil open or not connected
Replace controller
Verify solenoid welded, replace solenoid
Check for additional electronics attached to
B+, replace controller
Check wiring.
Replace power harness and motor if required.
Walkaway relay coil shorted.
Controller defective.
Replace controller
Contactor or walkaway coil relay shorted
Check M- wiring and repair, replace controller
Check walkaway circuit fuse & check walkaway relay
Replace controller
Check coil connections/wiring.
Replace solenoid if necessary
Walkaway relay coil short to ground
Controller defective
Check walkaway circuit fuse & check
walkaway relay.
Main contactor defective
P/N 73398G01