Cub Cadet Fun Runner User Manual
Revision 1
April 2001
1-1
1-2
TABLE OF CONTENTS
INTRODUCTION ............................................SECTION 1
COMPONENT DISCRIPTIONS......................SECTION 2
Battery Pack...................................................................... 2-1
Battery charger.................................................................. 2-2
Electric Drive Motor........................................................... 2-3
Motor Controller ................................................................ 2-3
Instrument Cluster............................................................. 2-5
ELECTRICAL & CHEMICAL SAFETY............SECTION 3
High Voltage Safety.......................................................... 3-1
Chemical Safety................................................................ 3-3
REMOVAL & INSTALLATION.........................SECTION 4
Canopy.............................................................................. 4-3
Utility Bed.......................................................................... 4-7
Motor/Speed Sensor......................................................... 4-9
Motor Contactor.............................................................. 4-15
Controller ........................................................................ 4-19
Battery Modules.............................................................. 4-23
Battery Charger............................................................... 4-29
Lights .............................................................................. 4-33
Headlight, Horn, Hazard Light Switches..........................4-35
Ignition Switch................................................................. 4-37
Turn Signal Switch.......................................................... 4-39
Accelerator Pot (Throttle Sensor).................................... 4-41
Instrument Cluster........................................................... 4-43
Park Brake Switch........................................................... 4-45
Brake Light Switch .......................................................... 4-47
Horn................................................................................ 4-51
TEST PROCEDURES.....................................SECTION 5
Ignition Switch & Jumper Harness.................................... 5-3
Accelerator Pot (Throttle Sensor)...................................... 5-9
Motor............................................................................... 5-11
Motor Contactor.............................................................. 5-15
Speed Sensor................................................................. 5-19
Brake Switch................................................................... 5-21
Park Brake Switch........................................................... 5-23
Directional Signal Switch................................................. 5-25
Instrument Cluster........................................................... 5-27
Charger........................................................................... 5-29
Battery Pack Evaluation.................................................. 5-31
1-3
TROUBLESHOOTING....................................SECTION 6
Fault Indication Table........................................................ 6-2
Motor Will Not Operate...................................................... 6-4
Nothing Works .................................................................. 6-5
Will Not Operate In All Modes........................................... 6-6
Horn Does Not Work......................................................... 6-7
Battery Charger Does Not Operate................................... 6-7
Low Range........................................................................ 6-8
Temperature Gauge.......................................................... 6-8
Battery Gauge................................................................... 6-8
Speedometer Does Not Work ........................................... 6-9
Instrument Cluster LED Indicators.................................. 6-10
Headlights & Taillights..................................................... 6-11
Rear Lights...................................................................... 6-12
Front Lights..................................................................... 6-12
Hazard Lights.................................................................. 6-13
Brake Lights.................................................................... 6-13
Directional Signals .......................................................... 6-14
Twist Lock Connector Pinouts......................................... 6-15
1-4
SECTION 1: INTRODUCTION
The FunRunner is an all-electric utility vehicle.
The energy for the FunRunner’s propulsion as
well as the operation of its lights, instruments,
horn, and etc., come from its 48-volt battery
pack. Being electric, the FunRunner emits no
exhaust and is therefore a zero emissions
vehicle. It is an environmentally friendly vehicle.
The FunRunner is also much quieter than an
internal combustion vehicle. It is well suited for
use in areas that are considered noise sensitive
or indoors where harmful gasoline emissions are
a concern.
Because gasoline powered vehicles have
electrical systems for cranking, ignition, lights,
etc., some of the service procedures used with
them are similar to those used with the
FunRunner. Other procedures will be unique to
the FunRunner.
The main components of the FunRunner are the
battery pack, electric motor, controller, battery
charger, and instrument cluster. The
FunRunner uses a 48V battery pack that is
considered to be high voltage.
voltage can be dangerous and requires an
extra measure of safety procedures not
normally associated with the service of
gasoline vehicles and equipment.
The high
Figure 1-1: FunRunner
1-1
1-2
SECTION 2: COMPONENT DESCRIPTION
Battery Pack
The battery pack of the FunRunner consists of
four 12-volt sealed lead acid battery modules.
The modules are situated in the vehicle under
the seat and are covered by the rear body panel.
See Figure 2-1. Since the modules are sealed
and valve regulated, no water or electrolyte can
be added to the batteries.
Figure 2-1:
Each module has a rated capacity of 73 amperehours (Ah) at a 20-hour discharge rate and 48
Ah at the 1-hour discharge rate. The capacity is
the available quantity of electricity in a battery
measured in Ah. Capacity is always related to
some quantity of current in amperes (amps) and
the length of time that the given current can be
produced. The minutes of reserve is a capacity
rating in which the amount of current is set at a
given rate, usually 25 amps, then the length of
time it takes for the battery to reach its
discharged cut-off voltage is measured. This
amount of time in minutes is the reserve
capacity of the battery.
For an electric vehicle like the FunRunner, the
capacity available from the batteries determines
the range of the vehicle. The range is the
distance that can be driven on one battery
charge.
temperature for rating a battery is 78°F. At
temperatures above 78°F, the capacity will be
higher than the rated capacity. The capacity will
be lower than rated capacity when temperatures
are below 78°F. At 32°F only about 70 percent
of the rated capacity is available. This is
significant, because if the FunRunner is
operated when the temperature is around 32°F,
the range will be reduced by 30 percent.
Another factor effecting capacity is the rate of
discharge. The battery modules in the
FunRunner are rated at 73 Ah for the 20-hour
rate and 48 Ah for the 1-hour rate. That’s a
large difference in the available Ah’s produced
between the two discharge rates. At the 20-hour
rate, the current drawn from the battery is set to
a low value that will take 20 hours to bring the
battery down to its cut-off voltage. The rate of
current in amps times the 20 hours is the
capacity rating. At the 1-hour rate, the current is
set at a much higher rate to bring the battery
down to the cut-off voltage in one hour. With a
73 Ah rating for 20 hours and a 48 Ah rating for
1 hour, it is obvious that the higher the rate of
current draw, the lower the capacity.
The FunRunner will use current at a fairly high
rate, and the higher the rate the shorter the
range will be. If it is driven faster or up hill
frequently, then the current rate will be higher
and the capacity of the battery pack will be
reduced.
The normal chemical process in the battery over
time will reduce the amount of active material on
the plates of the battery. This reduction in active
material will cause a reduction in capacity. In
other words, as the battery ages and more and
more charge/discharge cycles have occurred,
the capacity of the battery will begin to
decrease. When the aging process of the
battery has caused a decrease in capacity so
that the FunRunner no longer has a useable
range, the batteries must be replaced.
The normal driving range of the FunRunner is
approximately 30 miles when the batteries are
performing at their rated capacity. The battery
capacity and therefore the range can be affected
by several factors however.
Temperature has a dramatic effect on a lead
acid battery’s capacity. The standard
The four battery modules of the FunRunner are
wired in series to form a 48-volt battery pack.
When connecting battery modules in series, the
voltage of the pack is the total of the modules in
the series string. See Figure 2-2.
2-1
Figure 2-3:
Figure 2-2:
The modules must be connected from the
positive terminal of one module to the negative
terminal of the next. The one positive and one
negative terminal remaining on the modules are
the main terminals. The voltage at the main
terminals is 48V nominal.
When battery modules are connected in series,
the voltage of the system is added (i.e. 48 volts)
and the capacity of the modules not added. The
capacity of the series string is equal to the
capacity of one module. In fact, the capacity of
the series string is actually equal to the module
with the least capacity. However, because the
voltage is four times higher, the power and
energy of the pack is four times that of one
module.
As the capacity of the battery is reduced by the
various factors, the power of the battery is
normally not effected. The energy (power used
over time) is reduced however. This means that
no loss of speed, acceleration, or feel of power
will be experienced when a battery pack’s
capacity is reduced. A battery pack with only 15
Ah capacity wi ll have the same power as one
with 48 Ah capacity when both are fully charged.
What will be noticed is a reduction in the range
of the vehicle.
The charger receives its power from a 110 VAC
outlet when a cord is plugged into the charger
input connector located in the front of the rear
body panel below the seat. The AC power is
converted to DC and conditioned to the proper
voltage and current output levels to charge the
battery. It will take the charger about 7-8 hours
to restore a battery pack from fully discharged to
fully charged.
Located on the top of the battery charger are
one green and one red LED. See Figure 2-4.
During charging, the red LED is illuminated.
When the battery pack reaches a full charge, the
green LED will come on and the red LED will go
out. These LED indicators are not visible unless
the trunk basket panel is removed. The battery
charge gauge on the instrument panel cluster is
the indicator normally used for state of charge
reference.
Battery Charger
The FunRunner has an on-board battery charger
located at the rear of the vehicle just in front of
the rear bumper. See Figure 2-3. The function
of the charger is to replenish the used energy
from the battery pack.
Figure 2-4:
The battery charger is designed to never
overcharge or overheat the batteries due to
prolonged charging. Leaving the charger
plugged in will allow it to maintain a full charge
2-2
without overcharging. It is desirable to leave the
charger plugged in for long periods periodically
to equalize the charge of the battery pack
modules. Doing this will increase batt ery life.
Electric Drive Motor
The FunRunner uses a 48-volt brush type DC
motor. The motor uses permanent magnets for
the field and has a wound armature with a
commutator that the brushes ride on. See
Figure 2-5.
Motor Controller Assembly
The motor controller assembly on the
FunRunner is located just ahead of the trunk
basket panel under the rear body section. See
Figure 2-7. The controller is rated at 150 amps
and 48 volts. It is a four-quadrant controller that
uses pulse width modulation. The four-quadrant
design allows the motor to be reversed,
eliminating the need for a mechanical reverse
gear. The pulse width modulation ensures
smooth acceleration and power de li very while
operating at an extremel y high effic ienc y level.
Figure 2-5:
The motor is connected to the rear wheels
through a fixed ratio drive axle with differential.
Reverse for the FunRunner is accomplished by
reversing the direction of rotation of the electric
drive motor. There are no reverse gears in the
drive assembly. The motor receives power from
the controller.
The motor has no serviceable parts and is
replaced as an assembly if it fails. There is a
speed sensor located on the spacer between the
motor and drive axle. The speed sensor is
supplied as a service part. See Figure 2-6.
Figure 2-6:
Figure 2-7:
Figure 2-8:
The controller can be switched to either high or
low forward speeds or reverse. See Figure 2-8.
When selected to high speed, the controller will
allow a maximum speed of 12 mph. In low
speed mode, the controller will reduce the output
voltage as needed to reduce the max speed to 8
mph. Reverse mode is 6 mph maximum.
2-3
Of course, the controller must be able to provide
fully variable speed in each drive mode. The
throttle sensor is attached to the accelerator
pedal assembly and wired as an input to the
controller. See Figure 2-9. The sensor is a
potentiometer (a type of variable resistor often
called a pot) that will give a continual ly variable
signal from the fully released to fully depressed
pedal positions.
Figure 2-9:
The controller will monitor the throttle sensor
signal and adjust the output voltage to the motor
according to the demands of the operator
through the accelerator pedal.
The controller is also equipped with regenerative
braking. Regenerative braking is a feature
where the motor becomes a generator when the
vehicle is coasting or stopping. The kinetic
energy of the vehicle is turning the armature of
the motor through the permanent magnet field
producing a current in the armature that goes to
the controller. The current produced is opposite
of that used by the motor to drive the vehicle.
The controller will pass this current to the battery
pack replenishing a small portion of its charge.
The regenerative braking provides two benefits:
it increases range by adding some charge to the
battery pack and provides braking action that
assists the mechanical brakes. You can feel the
regenerative braking when re le asing the
accelerator even if the brake pedal is not
depressed.
The brake switch is connected to the controller
so that when the controller sees an input
indicating the brake has been depressed, it will
not allow power to flow to the motor even if the
accelerator pedal is depressed. See Figure
2-10.
Figure 2-10:
A signal is sent from the charger to the controller
during charging of the FunRunner. When the
controller senses the charging signal, none of
the propulsion modes can be activated. The
output from the charger passes thru the
controller to the batteries.
The FunRunner’s motor controller is unique in
that it controls all of the electrical systems on the
vehicle in addition to the motor. The controller
supplies power to each electrical system when
an input to the controller for the particular
system is activated. You can think of the
controller as a relay for each system. It
operates in a manner similar to a starter relay
connecting power to the starter when the ignition
or start switch energizes the coil of the relay.
An example of this would be the headlights.
The controller sends a voltage to the headlight
switch and monitors this voltage to see if it is
returned (pulled low) by the switch. When the
headlight switch is turned on, it closes
connecting the voltage to the return and the
controller sees the headlight switch wire pulled
low. The controller responds by supplying 12
volts to the headlight and taillight bulbs. The
headlight switch does not feed power directly to
the lights.
Other systems such as turn signals, brake lights,
hazard lights, horn, parking brake indicator and
etc., are controlled in the same way. These are
systems activated by the person operating the
vehicle. The controller will give outputs to other
electrical systems based on inputs not activated
by the operator. Examples are the state of
charge gauge and the speedometer. The
controller will adjust the state of charge meter
based on battery pack voltage. The controller
2-4
will output a signal to the speedometer based on
an input from the speed sensor.
All of the controller inputs and outputs are
shown in Figure 2-11. The diagram shows how
the controller is the master of the electrical
systems on the FunRunner.
Figure 2-11
Instrument Cluster
The instrument cluster has three indicator
gauges across the top and several LED
indicators along the bottom of the cluster. See
Figure 2-12. The cluster is the inform ation
center for the operator.
Figure 2-12:
The center gauge is a speedometer with
odometer. The temperature gauge is on the left
and it displays the temperature of the controller
heat sink. The battery gauge is on the right side
and it displays the state of charge of the battery
pack.
The fault, temperature, battery, reverse, on,
high, low, charging, park brake, and headlights
indicators make up the bottom row of LED’s.
Above these indicator lights are the turn signal
indicators. These lights will illuminate when the
corresponding signal of its function is activated.
The fault, battery, charge, and temperature
indicators and an audible beep from the
controller are used to relay fault codes.
2-5
2-6
SECTION 3: ELECTRICAL AND CHEMICAL SAFETY
Electrical safety is foremost on the FunRunner,
since voltage levels present can cause severe
burns, shock, or death.
High voltage electric shock can cause muscle
contractions. A current of only 10mA can cause
muscles to contract. Hands that are exposed to
enough electrical current clinch
release their grip.
Even a small amount of current can cause body
tissue damage. Damage to tissue is caused by
heat generated from current flow. When the
heat passes a point where it can be dissipated,
the body tissue is burned.
Fibrillation
heartbeat, can be caused by electrical shock.
The current must pass through the body, such
as with a hand-to-hand connection, in order for
fibrillation to occur.
Arcing
across a circuit gap. The heat at the ends of an
arc can be four times the surface temperature of
the sun. Severe burns can be caused when a
person is near or in contact with an arc.
An arc can cause an electric
the expansion of the air and molten metal,
usually copper, from the rapid heating taking
place.
, the disruption of the body’s normal
occurs when electricity is discharged
tight and cannot
blast
. The blast is
The FunRunner is equipped with a master
disconnect switch. See Figure 3-1.
Figure 3-1:
The master switch is a safety device that allows
the battery pack voltage to be removed from the
controller. The switch is to be used to
disconnect the battery from the controller before
starting any repairs to the high voltage portion of
the vehicle.
The master switch is located behind the seat.
See Figure 3-2. It can be turned off by sliding
the seat forward, reaching behind the seat and
twisting the red knob. The knob can be pulled
off of the switch when in the off position to
ensure that it is not inadvertently turned back on.
High Voltage Safety Procedures
The FunRunner’s high voltage and low voltage
systems are isolated from chassis ground under
normal circumstances. You must touch both a
positive and negative point in the circuit in order
to receive an electric shock. You should never
ground any wire on the FunRunner to the
chassis. Doing so could put the operator and
any service personnel in danger.
Figure 3-2:
The FunRunner has high voltage in the
propulsion, charging and ignition switch circuits.
See Figure 3-3.
3-1
Figure 3-3: FunRunner High Voltage Wiring
Practicing safety around hig h vol tage (HV)
will protect you and those around you. Keep
in mind the following HV safety precautions:
•
Have ample light in the work area.
•
Do not work in wet or damp areas.
•
Use proper tools, equipment, and
protective devices.
•
Remove all jewelry and metallic items.
•
Keep your tools and equipment in good
condition.
•
Never assume that voltage is not
present; check it with a known good
meter or other test device.
•
Verify that any capacitors have been
discharged.
•
Never try to bypass or override a safety
device, such as a fuse, unless specified
to do so with an approved tool as
described by the manufacturer’s
procedures.
•
Always use the correct replacement
parts.
•
Never use water on an electrical fire;
have an approved fire extinguisher
available.
•
Use only one hand when possible.
•
Wear eye protection.
•
Never work on high voltage when you
are totally alone; someone else should
be present in case an emergency
arises.
•
Follow the manufacturer’s procedures.
•
Take your time, think first and do not
rush.
•
Know emergency policies and
procedures for your work area.
•
Wear natural fabric clothing such as
cotton; polyester clothing will melt to
the skin when exposed to electrical
arcs.
•
Use insulated tools and inspect them
regularly for damaged insulation.
•
Know where eyewash stations, fire
extinguishers, reach poles and other
safety equipment is located.
•
Never lay tools or any conductive
material on any HV component or
battery pack.
The longer someone is in contact with an
electrical current, the less chance there is
for survival. The victim may stop breathing
and become somewhat stiff. In the case of
electrical shock, the following procedures
should be followed:
•
Call 911 or the appropriate emergency
numbers for your area.
•
Break the electrical connection as
quickly as possible, but do not expose
yourself to any electrical current.
•
If the current cannot be removed, use a
fiberglass reach pole or a dry board to
separate the victim from the circuit. Do
not touch the victim with your bare
3-2
hands until you are sure they have
been removed from the electrical
current.
•
If the victim has stopped breathing or
his/her heart is not pumping, use CPR
until help arrives. Only a trained
person should administer CPR.
•
If the victim must be moved, take
precautions in doing so. Use a
stretcher if possible.
Fire is always a possibility when working on
an electric vehicle. High voltage and
chemical batteries have the potential to
cause both fire and explosion when a faulty
condition exists.
Work areas should be clean and not
cluttered with combustible materials.
Flammable liquids should be stored in
approved storage areas.
You should know the location of fire
extinguishers and fire alarms. You should
also know how to contact the fire
department. Make sure you know how to
operate the fire extinguishers and what type
of fire they are rated for. Figure 3-4 shows
the classes of fires. Fire extinguishers
should be inspected monthly to verify they
have a full charge.
Figure 3-4:
eyes. The neutralizing agent for sulfuric
acid is bicarbonate soda. One pound of
soda dissolved in one gallon of water makes
a good neutralizing solution that can be
used in a spray bottle or poured on a spill.
When sulfuric acid contacts the skin, eyes,
or clothing, the first line of defense is water
and plenty of it. Flush the area with clean
water and soda mixture for 15 minutes. If
there is not enough soda-water mixture to
flush for 15 minutes, continue to flush with
clean water for a minimum of 15 additional
minutes and get prompt medical atten tio n.
If acid is accidentally swallowed, drink large
quantities of milk or water, followed by milk
of magnesia, a beaten egg, or vegetable oil.
Consult a physician immediately.
Chemical Safety
Batteries in the FunRunner contain
electrolyte that is very corrosive. Contact of
electrolyte with skin or eyes should be
avoided.
The FunRunner uses sealed batteries that
contain electrolyte in a gel between the
plates. While these types of batteries
cannot spill large amounts of electrolyte,
care should still be taken to avoid chemical
contact with the skin and eyes.
When working around batteries where there
is the possibility of chemical exposure, eye
protection should be worn, rubber gloves
and a rubber apron are recommended. An
emergency shower and eye wash stat ion
should be available as well as a first-aid kit
and electrolyte neutrali zing solu tio ns .
Lead acid batteries have a sulfuric acidwater solution as the electrolyte. Sulfuric
acid is very corrosive and can burn skin and
3-3
3-4
SECTION 4: REMOVAL & INSTALLATION
Canopy................................................................4-3
Utility Bed............................................................4-7
Motor/Speed Sensor...........................................4-9
Motor Contactor ................................................4-15
Controller ..........................................................4-19
Battery Modules................................................4-23
Battery Charger.................................................4-29
Lights ................................................................4-33
Headlight, Horn, Hazard Light Switches............4-35
High/Low/Reverse Switch..................................4-37
Turn Signal Switch............................................4-39
Accelerator Pot (Throttle Sensor)......................4-41
Instrument Cluster.............................................4-43
Park Brake Switch.............................................4-45
Brake Light Switch.............................................4-47
Horn..................................................................4-51
4-1
Figure 4-1
Figure 4-2 Figure 4-3
Figure 4-1A
4-2
SECTION 4: CANOPY INSTALLATION & REMOVAL
PARTS REQUIRED
710-0642 Hex Washer Screw 1/4-20 x .75 (8)
736-0342 Flat Washer .283 ID x .75 OD (12)
731-2337 Canopy Panel
749-1265 Rear Canopy Frame
749-1266 Front Canopy Frame
710-0136 Hex Cap Screw 1/4-20 x 1.75 (2)
710-1122 Hex Cap Screw 1/4-20 x 2.5 (2)
750-1298 Spacer .280 ID x 437 OD x .250 Lg (2)
750-1299 Spacer .280 ID x 437 OD x .850 Lg (2)
TOOLS REQUIRED
Phillips head screwdriver - #2
3/16” Allen wrench
Note: you may need one person to help.
STEP DETAILS
Get tools and check parts. See list above.
Assemble molded canopy and supports
(Figure 4-1).
Install canopy and support assembly.
Note: Nylon bushings are installed between
the vehicle body and the threaded screw
holes used to fasten the canopy supports.
Be careful to place bushings in position
properly.
Note: Screws have spacers under
canopy supports that must be installed to
protect body from deflection (Figure 1A).
Align screw holes with holes in supports.
Install and tighten Hex washer screws with
flat washers through canopy into threaded
holes in supports.
Remove two cap plugs on top of body just
behind seating area.
Remove two Allen screws and spacers on
top of body directly in front of the dash.
Insert the shorter spacers in the front holes
and the longer spacers in the rear holes.
Gently set canopy/support assembly on
vehicle with curved end facing to the front.
(Figure 4-2).
Insert and tighten Hex cap screws with flat
washers in front and rear supports. Tighten
to 65 to 75 in. lbs. (Figure 4-3).
Save extra parts. Store Allen screws for use if top is removed.
4-3
4-4
Remove canopy assembly. Remove 4 Hex cap screws from supports and
set canopy assembly aside.
Remove spacers and store screws.
If canopy assembly is not to be replaced, place
cap plugs in rear body section and install
original Allen screws and spacers in front body
panel
Remove molded canopy.
Note: If canopy is to be re-installed, this step
is not necessary.
Remove 8 Phillips head, ¼” x ¾” screws from
canopy.
Lift canopy from supports and set aside.
Store screws for replacing canopy.
4-5
Figure 4-4
Figure 4-5
Figure 4-6
4-6
UTILITY BED INSTALLATION
PARTS REQUIRED
607-0013 Utility Box Assembly
710-1832 Machine Screw 1/4-20 x 2” (4)
736-0173 Flat Washer .28 ID x .74 OD (4)
#2 Phillips screwdriver
1/16” Allen wrench
STEP DETAILS
Remove rear trunk lid and trunk basket
(Figure 4-4).
Remove body retaining screws
(Figure 4-5).
Raise cover so hinge rod is visible.
Loosen 1/16” Allen set screw on each hinge rod
locking collar.
Slide hinge rod toward one side to remove rod,
spacers and trunk lid.
Be careful not to loose spacers. Remove trunk
basket.
Remove 4 Phillips head screws and washers
holding body to frame around storage area.
Disconnect trunk lock from back of vehicle by
removing the two cap screws.
TOOLS REQUIRED
Store screws for possible future use.
Install utility bed (Figure 4-6). Place bed on frame so tailgate is to the rear.
Line up holes in bed with holes in frame.
Install 4 screws and flat washers provided
through bed into frame.
Tighten screws to 40-45 in. lbs. and check bed
secure.
Clean up. Store parts and tools.
4-7
Figure 4-7
Figure 4-8
Figure 4-9
Figure 4-10
4-8
MOTOR/SPEED SENSOR REMOVAL & INSTALLATION
TOOLS REQUIR ED
Wrenches - 3/8”, 1/2”, 9/16”, and 5/8” - socket and box end preferred
Pliers
Lift or jack - suitable for raising rear of vehicle and being clear when axle/wheel assembly is slid
out to the side.
Phillips screwdriver - #2
Allen wrench – 3/16”
STEP DETAILS
Make vehicle safe and accessible.
WARNING:
IF MASTER POWER SWITCH IS NOT OFF
BATTERY IS STILL CONNECTED TO
CONTROLLER. USE EXTREME CARE TO
AVOID INJURY OR DAMAGE.
Turn master power switch to off. Key operated switch mounted below
Disconnect motor cables from contactor and
controller (Figure 4-7).
Note: use care that washer or nut cannot fall
into motor.
Remove skid plate (Figure 4-8). From under motor.
Make sure switch is off and key removed.
Place chocks under all 4 wheels, front and
back of each wheel if any chance of rolling.
Remove utility bed if installed (4 screws)
Remove storage compartment.
controller.
Disconnect motor lead from motor side of
contactor.
Move controller as necessary to reach left side
power cable terminals.
Disconnect top-front power cable on lef t sid e
of controller (goes to motor).
Front cable connected with 9/16” nut and star
washer. (rear cable connected with 5/8” nut
and star washer. Do not remove for this step).
Fastened to frame in front and rear of motor
with 4 screws, ¼” x ½” with 3/8” hex head.
.
Disconnect brake cables (Figure 4-9). From rear brake levers, right and left rear
wheels.
Pull spring pins from brake cable retaining
pins.
Lift retaining pins from cable shackles.
Disconnect speed sensor. Unfasten differential
support bracket (Figure 4-10).
Unplug (plug in line inside rear compartment).
Bracket is bolted to frame with two large
washers on outside of frame.
4-9
Figure 4-11
Figure 4-12
Figure 4-13
Figure 4-14
Figure 4-15
4-10
Warning:
After axle assembly is completely loosened,
motor can fall and catch a hand unless care
is used. Suggest a block be placed under
differential bracket before axle is completely
loosened.
Disconnect motor support bracket
(Figure 4-11).
Bolted to motor and frame on left side of
vehicle.
2 bolts, ¼” x ½” - need 3/8” wrench.
Remove axle mounting brackets
(Figure 4-12).
Slide axle assembly from under vehicle
(Figure 4-13).
Remove motor (Figure 4-14). Place support under motor.
Remove parts from motor. Slide coupler and speed sensor cog from
Need ½” box end and ½” ratchet wrenches.
Attach lift to rear of frame, or use floor jack,
and raise vehicle high enough to slide rear
axle/motor assembl y out to side.
Place supports under rear of battery pack to
be sure vehicle cannot fall.
Use 3/16” Allen wrench to remove two
mounting screws.
Tilt rear of motor down and remove from drive
axle.
motor shaft.
Remove motor support bracket -two bolts -
3/8” wrench.
Loosen 1/8” Allen screw in end of spacer and
unscrew speed sensor.
Install parts on new motor (Figure 4-15). Bolt motor support bracket to new motor.
Insert speed sensor cog and coupler into
spacer and onto new motor shaft.
Install speed sensor in spacer.
Set speed sensor depth. Make sure speed sensor cog is inserted on
motor shaft
Screw speed sensor into spacer until it
touches cogs on sensor gear.
Unscrew speed sensor ¾ to 1 turn and make
sure it does not touch cogs when motor turns.
Tighten set screw to lock speed sensor in
place. Caution: do not over tighten set screw
causing damage to sensor threads.
4-11
Figure 4-16
Figure 4-17
4-12
Install new motor on axle assembly. Place motor on support so differential can be
rotated and lined up with motor.
Mate motor to differential with speed sensor
pointing away from axle. Make sure speed
sensor cog and coupler are in place.
Replace motor mounting screws using 3/16”
Allen wrench. Tighten securel y.
Mount axle assembly on vehicle. Slide assembly under rear of vehicle and
locate close to proper position.
Place block under differential support bracket
so bracket will be in position when ve hic l e is
lowered.
Lift vehicle slightly and remove supports from
under battery pack.
Slowly lower vehicle while adjusting position of
axle assembly so assem bl y will be in proper
position when vehicle is com pletely down on
the axle.
Bolt differential and motor supports to frame.
Install axle mounting brackets and tighten.
Connect brake cables. Place pins, from the top, through shackles and
brake levers.
Insert spring pins into brake connecting pins.
Connect motor power cables (Figure 4-16). Negative cable goes to top-front terminal on
left side of controller.
Positive cable with red terminal cover goes to
terminal on motor side of contactor.
Mount controller (Figure 4-17). Bolt mounting plates to frame (4 bolts).
Connect speed sensor. Plug into connection inside rear compartment.
Test unit. Turn on master power switch and test for
normal operation.
Install utility bed (if appropriate). Line up 4 bolt holes, install and tighten bolts.
4-13
Mounting
Mounting
Screws
Screws
From
From
Controller
To
To
Motor
Motor
Figure 4-18
Figure 4-20
Activation Wire
Activation Wire
Terminals
Terminals
Figure 4-19
Figure 4-21
From
From
Controller
Controller
Figure 4-22
4-14
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