Power Supply; Accessory Wiring; Check Green Power Wire; Light Bulb Replacement - Cushman Shuttle 2 Service Manual

Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

POWER SUPPLY

Tool List
DVOM ......................................................................... 1
1. CHECK FOR LOOSE OR BARE WIRES
Check for loose wires at each terminal connection
and for worn insulation or bare wires touching the
frame. Bare wires may cause a short circuit.
NOTICE
If any DVOM readings indicate a faulty wire, it is recom-
mended that the condition of the terminals and wire junction
be examined. A faulty wire should be replaced with one of the
same gauge and color and wired between the correct compo-
nents and wire tied to the harness bundle. The faulty wire
should be cut back close to the harness and the ends pro-
tected with vinyl electrical tape.
2. CHECK BATTERY CONDITION
Check for adequate battery volts (nominal 12 VDC)
by setting DVOM to 30 VDC range and place the red
probe (+) to the middle negative (-) battery post with
the green wire attached. Place the black probe (-) to
the first negative (-) battery post on the driver side
with the black wire attached. A reading of 11 VDC or
greater indicates adequate battery condition. No
reading indicates (a) a poor connection between the
probes and the battery terminals; (b) a faulty DVOM.
A voltage reading below 11 volts indicates poor bat-
tery condition and the vehicle should be recharged
before proceeding with the test.
NOTICE
Due to the resistance of the wires involved within the harness,
voltage readings may be somewhat lower than battery volt-
age. A reading of 1 volt below battery voltage is acceptable.

3. CHECK GREEN POWER WIRE

Firmly attach black probe (-) to the first negative(-)
battery post on the driver side with the black wire
attached and the red probe (+) to the terminal on the
side of the fuse block where the green wire is con-
nected. A reading of battery voltage indicates that the
green wire is in good condition.
Qty
The green wire supplies power to the entire fuse block.
4. CHECK FUSE
Place the red probe (+) to each wire terminal on the
fuse block. A reading of battery voltage indicates that
the fuse is in good condition. No reading indicates a
faulty fuse; replace with a good 15 amp fuse.

ACCESSORY WIRING

After determining that there is power to the fuse panel,
and the fuse is good, continue checking the circuit using
the procedures previously used to check the power sup-
ply, i.e. loose or rusted connections, bare wires, conti-
nuity of the wiring from terminal to terminal, operating
condition of switch, etc.
Use the wiring diagram (Ref. Fig. 2), and illustrations
(Ref Figs 3, 4 and 5 on pages H-4, 5 and 6) to check
correct wiring and wire routing. If there is power at the
fuse end of the wire, there must also be power at the
other end of the wire at the switch or electrical acces-
sory, and eventually at the ground connection. Electric-
ity must flow from the fuse panel through the full length
of the circuit to the ground connection. Any interruption
of electricity flow must be corrected, whether by repair-
ing or replacing the wire, the switch or accessory.

LIGHT BULB REPLACEMENT

To prevent premature bulb failure, do not touch new
bulbs with bare fingers. Use a clean, dry tissue or paper
towel to handle the glass portion of the bulb
Always hold bulbs with a clean, dry tissue or paper
towel. Natural oils from fingers will cause halogen bulbs
to fail prematurely.
Determine which bulb needs to be replaced. Reach
underneath light bar to access bulb from rear. Turn the
bulb socket a quarter turn counterclockwise to unlock
and pull out bulb. Insert new bulb and rotate quarter
turn clockwise to secure.
Locate bulb socket on backside of light bar (Ref. Fig. 3)
and turn bulb socket a quarter turn counterclockwise to
Repair and Service Manual
ELECTRICAL SYSTEM
NOTICE
B
B
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Page J-3