Troubleshooting - 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.
ELECTRICAL SYSTEM
For non-PDS vehicles, see Electronic Speed Control Section.
For PDS vehicles, see Electronic Speed Control (PDS) Section.
For PDS vehicles, also use Diagnostic Mode, PDS Fault Codes and Troubleshooting Diagrams.
Condition
VEHICLE WILL NOT MOVE
VEHICLE SPEED ERRATIC
NO REDUCED SPEED IN REVERSE Faulty ESC system
MOTOR NOISY
BATTERIES WILL NOT CHARGE
Possible Cause
Key 'OFF' or no direction selected
Batteries discharged
Batteries unable to be charged
Corroded or loose battery
connections
Corroded or loose battery connections
to ESC controller, direction switch or
motor
Solenoid has failed
Key switch has failed
Micro switch at direction selector
switch has failed
Connector(s) loose or separated
Faulty motor
Faulty ESC system
Ignition interlock switch has failed
Faulty ESC system
Damaged bearing
Raised commutator bar(s)
Loose motor mounting hardware
Charger not functioning correctly
Vehicle charging wiring faulty
Repair and Service Manual

TROUBLESHOOTING

Correction
Turn key 'ON' and select direction
Charge batteries
Load test and replace batteries that
cannot be charged
Clean and tighten battery connections
Apply a coat of commercial terminal
protectant to all terminals
Clean, tighten or replace faulty wiring
Replace solenoid
Replace key switch
Replace micro switch
Install connector(s) correctly
Repair or replace motor
Test by checking continuity of field
coils (S1 - S2) and armature (A1 - A2)
Check for continuity of armature to
ground and field coils to ground which
indicates a shorted condition
Test and replace components as
indicated by test procedure
Replace reed switch
Test and replace components as
indicated by test procedure
Test and replace components as
indicated by test procedure
Replace bearing
Replace motor
Tighten
Repair or replace charger
Repair or replace wiring
B
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