Cushman 632904 Service Manual page 63

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) 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 accessory, and eventually at the
ground connection. Electricity 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 repairing or replacing the wire,
the switch or accessory.
LIGHT BULB REPLACEMENT
Tool List
Wrench, 10mm ............................................................ 1
To reduce the possibility of premature bulb failure, do not
touch new bulbs with bare fingers. Use clean, dry tissue
or paper towel to handle the glass portion of the bulb.
Head light assembly are designed for a long life and do
not fail often. In case of failure the complete headlight
assembly is to be replaced and replacement for the sin-
gle headlight failed is not possible. Refer to Service
Parts Manual for the part number of the head light
assembly.
To replace the headlight assembly, locate the nuts in
back of the headlight assembly, underneath the cowl
Repair and Service Manual
ELECTRICAL SYSTEM
NOTICE
B
B
Qty.
Page F-3