Cub Cadet Fun Runner- User Manual

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 onenegative terminal remaining on the modules arethe main terminals. The voltage at the mainterminals is 48V nominal. When battery modules are connected in ...

2-5 will 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. The diagram shows how the controller is the master of the electricalsystems on the FunRunner. Figure 2-11 Instrument Cluster The instrument cluster has...

3-1 SECTION 3: ELECTRICAL AND CHEMICAL SAFETY Electrical safety is foremost on the FunRunner,since voltage levels present can cause severeburns, shock, or death. High voltage electric shock can cause musclecontractions. A current of only 10mA can causemuscles to contract. Hands that are exposed toen...

3-3 hands until you are sure they havebeen removed from the electricalcurrent. • If the victim has stopped breathing orhis/her heart is not pumping, use CPRuntil help arrives. Only a trainedperson should administer CPR. • If the victim must be moved, takeprecautions in doing so. Use astretcher if po...

4-3 SECTION 4: CANOPY INSTALLATION & REMOVAL PARTS REQUIRED 710-0642 Hex W asher Screw 1/4-20 x .75 (8)736-0342 Flat Washer .283 ID x .75 OD (12)731-2337 Canopy Panel749-1265 Rear Canopy Frame749-1266 Front Canopy Frame710-0136 Hex Cap Screw 1/4-20 x 1.75 (2)710-1122 Hex Cap Screw 1/4-20 x 2.5 (...

4-7 UTILITY BED INSTALLATION PARTS REQUIRED 607-0013 Utility Box Assembly710-1832 Machine Screw 1/4-20 x 2” (4)736-0173 Flat Washer .28 ID x .74 OD (4) TOOLS REQUIRED #2 Phillips screwdriver1/16” Allen wrench STEP DETAILS Remove rear trunk lid and trunk basket(Figure 4-4). Raise cover so hinge rod i...

4-9 MOTOR/SPEED SENSOR REMOVAL & INSTALLATION TOOLS REQUIRED Wrenches - 3/8”, 1/2”, 9/16”, and 5/8” - socket and box end preferredPliersLift or jack - suitable for raising rear of vehicle and being clear when axle/wheel assembly is slidout to the side.Phillips screwdriver - #2Allen wrench – 3/16...

4-14 Figure 4-18 Figure 4-19 FromController MountingScrews Activation WireTerminals From MountingScrews Activation WireTerminals Figure 4-20 FromController To Motor From Controller To Motor Figure 4-21 Figure 4-22

4-15 MOTOR CONTACTOR REMOVAL & INSTALLATION STEP DETAILS Make sure vehicle is safe. Switch off and key removed. Parking brake set. Remove canopy assembly (if installed). Remove utility bed (if installed). Remove 4 Phillips head screws. Lift bed off and set aside. Turn off master power switch. Lo...

4-19 CONTROLLER REMOVAL & INSTALLATION TOOLS REQUIRED ½” Socket wrench 9/16” wrench 5/8” wrench # 2 Phillips screwdriver Note: It is easier and safer to remove rear body section and disconnect batteries before removing/replacing controller STEP DETAILS Check vehicle safe status. Warning: Charged...

4-23 BATTERIES REMOVAL & INSTALLATION STEP DETAILS Make sure parts on hand. Batteries (total of 4 in vehicle)Deka - “Dominator”Model 8G24 - 12v Get required tools. #2 Phillips screwdriver5/8” wrench9/16” wrench1/2” ratchet wrenchInsulated pliers3/16” Allen wrench Make vehicle safe. Switch off an...

4-29 BATTERY CHARGER REMOVAL & INSTALLATION STEP DETAILS Get required tools. #2 Phillips screwdriver½” wrenches (2)Tool for cutting tie wraps Note: charger cable runs from receptacle onfront of rear body section to charger mounted onrear of vehicle frame. Check machine safe. Switch off and key r...

4-33 LIGHTS REMOVAL & INSTALLATION STEP DETAILS Make vehicle safe. Switch off and key removed. Parking brake set. Replace turn signal bulb (Figure 4-44). Twist turn signal receptacle about ¼ turncounterclockwise and remove from fixture. Unplug bulb and replace. Insert receptacle into fixture and...

4-37 IGNITION SWITCH REMOVAL & INSTALLATION STEP DETAILS Make sure vehicle safe. Switch off and key removed. Set parking brake. Turn master power switch off (behind seat). Warning: Voltage is applied to the switch unless the master power switch is off. Be careful. Remove switch (Figure 5-50). Re...

4-39 TURN SIGNAL SWITCH REMOVAL & INSTALLATION STEP DETAILS Make sure vehicle safe. Switch off and key removed. Set parking brake. Remove switch (Figure 4-52). Use screwdriver to gently pry switch out frompanel. Unplug switch. Install new switch (Figure 4-53). Plug new switch into wiring harness...

4-43 INSTRUMENT CLUSTER REMOVAL & INSTALLATION STEP DETAILS Make sure vehicle is safe. Switch off and key removed. Set parking brake. Pry instrument cluster loose from panel(Figure 4-56). Use care to not damage cluster or panel. Unplug instrument cluster (Figure 4-57). From wiring harness. Insta...

4-45 PARK BRAKE SWITCH REMOVAL & INSTALLATION STEP DETAILS Check machine safe. Switch off and key removed. Block wheels if necessary. Remove floor mat and guard plate(Figure 4-58). Pry plastic retaining pins loose. Be careful tonot tear floor mat. Guard plate lifts off when floor mat removed. Un...

4-47 BRAKE LIGHT SWITCH REMOVAL & INSTALLATION STEP DETAILS Check machine safe. Switch off and key removed. Block wheels if necessary. Remove floor mat and upper guard plate(Figure 4-62). Pry plastic retaining pins loose. Guard plate lifts off when floor mat removed. Uncouple brake cable connect...

4-51 HORN REMOVAL & INSTALLATION STEP DETAILS Make sure vehicle safe. Switch off and key out. Parking brake set. Adjust steering. Turn front wheels as far to the right aspossible. Horn is accessible through right wheel well. Disconnect horn (Figure 4-67). Remove spade connectors from tabs on hor...

5-1 SECTION 5: TEST PROCEDURES Ignition Switch & Jumper Harness ....................... 5-3Accelerator Pot (Throttle Sensor) ........................ 5-9Motor ................................................................. 5-11Motor Contactor ................................................ 5-...

5-5 JUMPER HARNESS TESTING PROCEDURES Step Details Jumper harness has resistors in the wiring and must be tested separately from the switch whenswitch malfunction is suspected. Problem might be in harness and not switch.An ohmmeter is required. Make vehicle safe. Switch off and key removed. Parking ...

5-7 IGNITION SWITCH TESTING PROCEDURES STEP DETAILS Make vehicle safe. Switch off and key removed.Parking brake set. Remove switch. Remove retainer nut and pull switch out fromback of panel. Unplug jumper harness from switch. Check switch continuity. See Figure 5-4. Use ohmmeter to check pins as sho...

5-11 MOTOR TEST PROCEDURES STEP DETAILS Make vehicle safe. Ignition switch off and key removed. Parking brake set. Remove utility bed (or storage compartment). Whichever is installed. Remove 4 screws from utility bed or lift storagecompartment out. Turn off master power switch. Located behind seat. ...

5-15 MOTOR CONTACTOR TEST PROCEDURES STEP DETAILS Make vehicle safe. Ignition switch off and key removed. Parking brake set. Turn off master power switch. Switch behind seat. Remove utility bed (or storage compartment). Whichever is installed. Remove canopy assembly. If installed, refer to Section 4...

5-18 Figure 5-11 1 2 3 Speed Sensor Battery Volts _ + blue black brown 1K Ω Sensor Plug 1 2 3 Speed Sensor Battery Volts _ + blue black brown 1K Ω Sensor Plug

5-19 SPEED SENSOR TEST PROCEDURES STEP DETAILS Remove utility bed. If equipped. Remove trunk basket. Lifts out. Test speed sensor using test tool. Note: This test can be done with a DMM,but it is more easily done with an analogvoltmeter. Test speed sensor without test tool.See Figure 5-11. Note: Thi...

5-21 BRAKE SWITCH TEST PROCEDURES STEP DETAILS Remove rubber floor mat. Pry out plastic retaining pins. Remove upper guard plate. Lifts off. Remove brake pull and lower guard plate. SeeFigure 5-12. Remove spring clip and clevis pin from brakepull. Remove two hex head bolts from lowerguard plate. Rem...

5-23 PARK BRAKE SWITCH TEST STEP DETAILS Remove rubber floor mat. Pry out plastic retaining pins. Remove upper guard plate. Lifts off. Test Switch. Note: Wires should be attached to twoupper terminals of switch. Note: check switch lever to make sure parkbrake mechanism is pushing and releasingswitch...

5-25 DIRECTIONAL SIGNAL SWITCH TEST STEP DETAILS Remove signal switch. Gently pry switch from dash. Remove signal switch. Test switch. See Figure 5-15. Test wires. See Figure 5-16. Set parking brake with switch plugged in andkey to an on position. Check instrument clusterto make sure the on light an...

5-27 INSTRUMENT CLUSTER TEST PROCEDURES (Nothing on cluster works but rest of vehicle ok) STEP DETAILS Remove instrument cluster. Gently and carefully pry cluster from dash. Unplug connector. From back of cluster. Check for power to cluster. Note: Pin locations are numbered on backof plug. Check wir...

5-29 CHARGER TESTING PROCEDURES It is important for the charger to operateproperly to completely charge the batteries,have a full range, provide long battery life,and do it all safely. The charger must supply current to thebattery pack to recharge it. As the batterypack accepts more current, the vol...

5-31 BATTERY PACK EVALUATION As batteries age and acquire more cycles onthem, they begin to loose capacity. A cycleis one complete charge and dischargeevent. The battery’s cycle life is the amountof charge/discharge cycles it can take beforeit no longer meets the minimum capacityrequirements. There ...

5-32 charger is operating properly, then thebattery pack capacity is most likely low.Note: Batteries that have lostcapacity will usually still have thesame power they had previously.For this reason the range of theFunRunner will be reduced, but theperformance of the vehicle whiledriving after a char...

6-1 SECTION 6: TROUBLESHOOTING Fault Indication Table.......................................... 6-2Motor Will Not Operate ....................................... 6-4Nothing Works .................................................... 6-5Will Not Operate In All Modes ............................. 6-6Ho...

6-2 FAULT INDICATION SYSTEM The controller on the FunRunner is equipped withonboard diagnostic help. The fault, battery, charge, andtemperature LED indicators on the instrument cluster aswell as an audible beep from the controller are used toindicate various faults. See Figure 6-1. Observing the lig...

6-3 Fault Indication Table Digits refer to Number of Pulses NNT = Non Neutral Throttle Fault Indicator Cause Action to Take Flt Bat Chg Tmp Audio Keyoff 1 Malfunction in key switch circuit Test key switch and switch circuit (including jumper). Cutback flash 2@NNT Battery voltage approaching lower li...

6-17 CONTROLLER TWIST LOCK CONNECTION PIN IDENTIFICATION Pin COLOR FUNCTION 57 pin connector 1 n/c 2 n/c 4 n/c 5 n/c 6 n/c 7 n/c 8 n/c 9 n/c 10 n/c 11 Org Contactor relay (positive) 12 Wht Contactor relay (negative) 13 Wht Auxiliary horn (positive) 14 Grn Auxiliary horn (negative) 15 n/c 16 n/c 17 n...