Cub-cadet Fun Runner Manuel d'utilisateur

1-1Revision 1April 2001

2-4Of course, the controller must be able to providefully variable speed in each drive mode. Thethrottle sensor is attached to the acceleratorpedal a

5-32charger is operating properly, then thebattery pack capacity is most likely low.Note: Batteries that have lostcapacity will usually still have th

6-1SECTION 6: TROUBLESHOOTINGFault Indication Table... 6-2Motor Will Not Operate ...

6-2FAULT INDICATION SYSTEMThe controller on the FunRunner is equipped withonboard diagnostic help. The fault, battery, charge, andtemperature LED ind

6-3Fault Indication TableDigits refer to Number of Pulses NNT = Non Neutral ThrottleFault Indicator Cause Action to Take Flt Bat Chg Tmp

6-4PROBLEM POSSIBLE CAUSES CORRECTIVE ACTIONMotor will not operate(lights and charger ok).Warning:Use care whenchecking motor andbattery voltages, 48V

6-5PROBLEM POSSIBLE CAUSES CORRECTIVE ACTIONNote: Charge indicator lightwould normally be on duringa charge inhibit but could bemalfunctioning.Note: B

6-6PROBLEM POSSIBLE CAUSES CORRECTIVE ACTIONFaulty controller. Switch Connector Lock ConnectorRed wire Pin 1toPin 30Black wire Pin 2toPin 31Wh

6-7PROBLEM POSSIBLE CAUSES CORRECTIVE ACTIONFaulty controller.readings should be less than 1 ohm.Main Harness KeyLarge TwistSwitch ConnectorLock Contr

6-8PROBLEM POSSIBLE CAUSES CORRECTIVE ACTIONBroken wire.Controller fault.switch.If no voltage to horn switch, checkcontinuity of green switch wire to

6-9PROBLEM POSSIBLE CAUSES CORRECTIVE ACTIONfor a gauge that will not moveup from the minimumposition.Note: Pin locations arenumbered on back ofconnec

2-5will output a signal to the speedometer based onan input from the speed sensor.All of the controller inputs and outputs areshown in Figure 2-11. T

6-10PROBLEM POSSIBLE CAUSES CORRECTIVE ACTIONFaulty controller.Speedometer will notwork (other instrumentcluster gauges andlights ok).Faulty speed sen

6-11PROBLEM POSSIBLE CAUSES CORRECTIVE ACTIONFaulty wire. Faulty controllerPin 19On lightPin 23High lightPin 24Low lightPin 15Charge lightPin 20Park l

6-12PROBLEM POSSIBLE CAUSES CORRECTIVE ACTIONPin 35High Pin 24toPin 34Low Pin 15toPin 42Charge Pin 20toPin 45Park Pin 8toPin 57Lights Pin 7toPin 49If

6-13PROBLEM POSSIBLE CAUSES CORRECTIVE ACTIONFaulty controllercontroller is at fault.If switch and switch circuit is ok,possibility of all bulbs burne

6-14PROBLEM POSSIBLE CAUSES CORRECTIVE ACTIONNo rear lights (frontlights ok).Open rear lights return path. Unplug main harness from tail/brakelight ha

6-15PROBLEM POSSIBLE CAUSES CORRECTIVE ACTIONFaulty controller.If switch and switch circuit is ok –possibility of all bulbs burned out,broken, or bad

6-16PROBLEM POSSIBLE CAUSES CORRECTIVE ACTIONon one side or both(other lights ok).No voltage to lights.Faulty controller.Unplug connector at light har

6-17CONTROLLER TWIST LOCK CONNECTION PIN IDENTIFICATIONPin COLOR FUNCTION57 pin connector1n/c2n/c4n/c5n/c6n/c7n/c8n/c9n/c10 n/c11 Org Contactor relay

2-6

3-1SECTION 3: ELECTRICAL AND CHEMICAL SAFETYElectrical safety is foremost on the FunRunner,since voltage levels present can cause severeburns, shock,

3-2Figure 3-3: FunRunner High Voltage WiringPracticing safety around high voltage (HV)will protect you and those around you. Keepin mind the followi

3-3hands until you are sure they havebeen removed from the electricalcurrent.• If the victim has stopped breathing orhis/her heart is not pumping, us

3-4

4-1SECTION 4: REMOVAL & INSTALLATIONCanopy...4-3Utility Bed...

4-2Figure 4-1Figure 4-2 Figure 4-3Figure 4-1A

4-3SECTION 4: CANOPY INSTALLATION & REMOVALPARTS REQUIRED710-0642 Hex Washer Screw 1/4-20 x .75 (8)736-0342 Flat Washer .283 ID x .75 OD (12)731-2

1-2

4-4

4-5Remove canopy assembly. Remove 4 Hex cap screws from supports andset canopy assembly aside.Remove spacers and store screws.If canopy assembly is no

4-6Figure 4-4Figure 4-5Figure 4-6

4-7UTILITY BED INSTALLATIONPARTS REQUIRED607-0013 Utility Box Assembly710-1832 Machine Screw 1/4-20 x 2” (4)736-0173 Flat Washer .28 ID x .74 OD (4)TO

4-8Figure 4-7Figure 4-8Figure 4-9Figure 4-10

4-9MOTOR/SPEED SENSOR REMOVAL & INSTALLATIONTOOLS REQUIREDWrenches - 3/8”, 1/2”, 9/16”, and 5/8” - socket and box end preferredPliersLift or jack

4-10Figure 4-11Figure 4-12Figure 4-13Figure 4-14Figure 4-15

4-11Warning:After axle assembly is completely loosened,motor can fall and catch a hand unless careis used. Suggest a block be placed underdifferentia

4-12Figure 4-16Figure 4-17

4-13Install new motor on axle assembly. Place motor on support so differential can berotated and lined up with motor.Mate motor to differential with s

1-3TABLE OF CONTENTSINTRODUCTION ...SECTION 1COMPONENT DISCRIPTIONS ...SECTION 2Battery Pa

4-14Figure 4-18Figure 4-19FromControllerMountingScrewsActivation WireTerminalsFromMountingScrewsActivation WireTerminalsFigure 4-20FromControllerToMot

4-15MOTOR CONTACTOR REMOVAL & INSTALLATIONSTEP DETAILSMake sure vehicle is safe. Switch off and key removed.Parking brake set.Remove canopy assemb

4-16

4-17Test operation. Turn on master power switch (behind seat).Make sure vehicle will operate properly.Install parts removed. Install rear body section

4-18Figure 4-23Figure 4-24Figure 4-25

4-19CONTROLLER REMOVAL & INSTALLATIONTOOLS REQUIRED½” Socket wrench9/16” wrench5/8” wrench# 2 Phillips screwdriverNote:It is easier and safer to r

4-20Figure 4-26Figure 4-28Figure 4-27Figure 4-29Figure 4-30Figure 4-31

4-21Disconnect motor and battery power cables(Figure 4-26).Note: it is a smart move to lay a cover overthe motor before removing cables. A loosewashe

4-22Figure 4-33Figure 4-34Figure 4-32

4-23BATTERIES REMOVAL & INSTALLATIONSTEP DETAILSMake sure parts on hand. Batteries (total of 4 in vehicle)Deka - “Dominator”Model 8G24 - 12vGet r

1-4TROUBLESHOOTING...SECTION 6Fault Indication Table... 6-2Motor

4-24Figure 4-35Figure 4-36Figure 4-37Figure 4-38Figure 4-39

4-25Disconnect batteries (Figure 4-35).Warning:Batteries are probably charged and “hot”.Use care to not short cables to frame orother battery terminal

4-26

4-27Install rear body section. Lift body section and work into position soscrew holes are lined up.Replace electrical tie wraps if necessary tohold ca

4-28Figure 4-42Figure 4-40Figure 4-41Figure 4-43

4-29BATTERY CHARGER REMOVAL & INSTALLATIONSTEP DETAILSGet required tools. #2 Phillips screwdriver½” wrenches (2)Tool for cutting tie wrapsNote: c

4-30

4-31Turn on master power switch. Located behind seat.Test charger. Make sure it is actually sending current to battery(voltage rises and charge status

4-32Figure 4-45Figure 4-44Figure 4-46 Figure 4-47

4-33LIGHTS REMOVAL & INSTALLATIONSTEP DETAILSMake vehicle safe. Switch off and key removed.Parking brake set.Replace turn signal bulb (Figure 4-44

1-1SECTION 1: INTRODUCTIONThe FunRunner is an all-electric utility vehicle.The energy for the FunRunner’s propulsion aswell as the operation of its

4-34Figure 4-48Figure 4-49

4-35HEADLIGHT, HORN, HAZARD LIGHT SWITCHESREMOVAL & INSTALLATIONSTEP DETAILSCheck vehicle safe. Switch off and key removed.Set parking brake.Remov

4-36Figure 4-50Figure 4-51

4-37IGNITION SWITCH REMOVAL & INSTALLATIONSTEP DETAILSMake sure vehicle safe. Switch off and key removed.Set parking brake.Turn master power switc

4-38Figure 4-52Figure 4-53

4-39TURN SIGNAL SWITCH REMOVAL & INSTALLATIONSTEP DETAILSMake sure vehicle safe. Switch off and key removed.Set parking brake.Remove switch (Figur

4-40Figure 4-54Figure 4-55

4-41ACCELERATOR POT (THROTTLE SENSOR) REMOVAL& INSTALLATIONSTEP DETAILSMake sure vehicle is safe. Switch off and key removed.Set parking brake.Rem

4-42Figure 4-56Figure 4-57

4-43INSTRUMENT CLUSTER REMOVAL & INSTALLATIONSTEP DETAILSMake sure vehicle is safe. Switch off and key removed.Set parking brake.Pry instrument cl

1-2

4-44Figure 4-58Figure 4-59Figure 4-60Figure 4-61

4-45PARK BRAKE SWITCH REMOVAL & INSTALLATIONSTEP DETAILSCheck machine safe. Switch off and key removed.Block wheels if necessary.Remove floor mat

4-46Figure 4-62Figure 4-63Figure 4-64Figure 4-65Figure 4-66

4-47BRAKE LIGHT SWITCH REMOVAL & INSTALLATIONSTEP DETAILSCheck machine safe. Switch off and key removed.Block wheels if necessary.Remove floor mat

4-48

4-49Connect brake cables. Install clevis on brake lever.Make sure clevis pin and spring pin aresecure.Check lights. Make sure brake light is operating

4-50Figure 4-67Figure 4-68

4-51HORN REMOVAL & INSTALLATIONSTEP DETAILSMake sure vehicle safe. Switch off and key out.Parking brake set.Adjust steering. Turn front wheels as

4-52

5-1SECTION 5: TEST PROCEDURESIgnition Switch & Jumper Harness...5-3Accelerator Pot (Throttle Sensor) ...

2-1SECTION 2: COMPONENT DESCRIPTIONBattery PackThe battery pack of the FunRunner consists offour 12-volt sealed lead acid battery modules.The modules

5-2SECTION 5: Figure 5-1Figure 5-2

5-3IGNITION SWITCH & JUMPER HARNESS TESTPROCEDURESSTEP DETAILSMake vehicle safe. Ignition switch off and key removed.Parking brake set.Disconnect

5-4Figure 5-3

5-5 JUMPER HARNESS TESTING PROCEDURESStep DetailsJumper harness has resistors in the wiring and must be tested separately from the switch whenswitch m

5-6Figure 5-4

5-7IGNITION SWITCH TESTING PROCEDURESSTEP DETAILSMake vehicle safe. Switch off and key removed.Parking brake set.Remove switch. Remove retainer nut an

5-8Figure 5-5Figure 5-6

5-9ACCELERATOR POT (THROTTLE SENSOR) TESTINGPROCEDURESSTEP DETAILSMake sure vehicle safe. Turn ignition switch off and remove key.Set parking brake.Ch

5-10Figure 5-7

5-11MOTOR TEST PROCEDURESSTEP DETAILSMake vehicle safe. Ignition switch off and key removed.Parking brake set.Remove utility bed (or storage compartme

2-2 Figure 2-2:The modules must be connected from thepositive terminal of one module to the negativeterminal of the next. The one positive and oneneg

5-12Figure 5-8

5-13 Test motor current draw (Figure 5-8).Note: Test should be done with driveronly, (no payload) and on level ground.If motor is weak, performance is

5-14Figure 5-9Figure 5-10

5-15MOTOR CONTACTOR TEST PROCEDURESSTEP DETAILSMake vehicle safe. Ignition switch off and key removed.Parking brake set.Turn off master power switch.

5-16

5-17Replace contactor if necessary. If voltage is present at activator terminals butdoes not cause contactor to close.If contactor closes but more tha

5-18Figure 5-111 2 3SpeedSensorBatteryVolts_+blueblackbrown1KΩSensor Plug1 2 3SpeedSensorBatteryVolts_+blueblackbrown1KΩSensor Plug

5-19SPEED SENSOR TEST PROCEDURESSTEP DETAILSRemove utility bed. If equipped.Remove trunk basket. Lifts out.Test speed sensor using test tool.Note: Th

5-20Figure 5-12Figure 5-13

5-21BRAKE SWITCH TEST PROCEDURESSTEP DETAILSRemove rubber floor mat. Pry out plastic retaining pins.Remove upper guard plate. Lifts off.Remove brake p

2-3without overcharging. It is desirable to leave thecharger plugged in for long periods periodicallyto equalize the charge of the battery packmodule

5-22Figure 5-14

5-23PARK BRAKE SWITCH TESTSTEP DETAILSRemove rubber floor mat. Pry out plastic retaining pins.Remove upper guard plate. Lifts off.Test Switch.Note: W

5-24Figure 5-15Figure 5-16

5-25DIRECTIONAL SIGNAL SWITCH TESTSTEP DETAILSRemove signal switch. Gently pry switch from dash.Remove signal switch.Test switch. See Figure 5-15.Tes

5-26Figure 5-17Figure 5-18

5-27INSTRUMENT CLUSTER TEST PROCEDURES(Nothing on cluster works but rest of vehicle ok)STEP DETAILSRemove instrument cluster. Gently and carefully pry

5-28

5-29CHARGER TESTING PROCEDURESIt is important for the charger to operateproperly to completely charge the batteries,have a full range, provide long ba

5-30If the charger performed all the stepsrequired, it is operating normally. If thecharger does not charge according to thisprocedure, it may underc

5-31BATTERY PACK EVALUATIONAs batteries age and acquire more cycles onthem, they begin to loose capacity. A cycleis one complete charge and discharge