Cushman MINUTE MISER, Technician'S Repair And Service Manual

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H
Page H-1
Repair and Service Manual
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings
TROUBLESHOOTING VEHICLE WIRING
Tool List Qty. Required
Digital Volt Ohm Meter (DVOM) .................................. 1
Symptoms
If the vehicle does not operate, operates poorly or inter-
mittently, the following test sequence should be followed:
Testing
Initial tests will be conducted with a Digital Volt Ohm
Meter (DVOM) to identify the failed component.
A typical DVOM is shown in illustrations. A recom-
mended DVOM is available through the Service Parts
Department as P/N 27481-G01. Any DVOM may be
used; however, the accuracy, controls displays and fea-
tures may vary depending on the make and model.
Always follow the meter manufacturer’s recommenda-
tions and instructions for the use and care of the meter.
To assure accurate readings, be sure to set the meter to
the closest voltage reading above the expected voltage.
To prevent unexpected
movement of the vehicle,
always raise the entire
vehicle before conducting any tests.
Never operate vehicle at full throttle for more than 4 -
5 seconds while vehicle is in a ‘no-load’ condition.
Raise the vehicle and support on jack stands (as speci-
fied in SAFETY section). Test the vehicle stability before
proceeding.
Examine all wiring of the controller to assure that all
wires are without physical damage or corrosion. Check
the routing of all wiring and the tightness of each connec-
tion. Repair or replace any suspect wires or connections.
Testing Battery Voltage
It is important to determine the condition of the battery
set before proceeding with any electrical troubleshooting.
An open voltage test is of little use since a battery that
has deteriorated to the point of requiring replacement will
still show six volts or better in an open voltage test. If
there is any doubt as to the adequacy of the battery set,
the batteries must be charged or replaced.
With the adequacy of the batteries confirmed, use a
DVOM connected directly to the battery terminal posts to
determine the open voltage of the set (Ref Fig. 1 on page
H-1). In the following tests, this voltage level will be used
as a reference. Some loss due to resistance of wires and
connectors may be indicated by readings that may be up
to one volt less than the reference voltage. No reading
indicates an ‘open’ condition and the power circuit should
be inspected for a broken or disconnected conductor.
Continuity Check
Before attempting to per-
form a continuity check,
turn the key switch to
‘OFF’ and place the direction selector in neutral.
Using an insulated wrench,
remove the negative (-) wire
from the battery to discon-
nect electrical power to vehi-
cle.
Turn the key switch to ‘OFF’ and place the direction
selector in neutral before disconnecting power by remov-
ing the B+ connection to the battery. Always use insu-
lated wrenches when working on batteries. To check
for continuity, set the DVOM to the K
Ω
setting and select
‘Continuity’. The meter will give an audible signal when it
detects continuity. If the meter does not have a continuity
setting, set it to K
Ω
, the meter will indicate ‘0’ when it
detects continuity.
! !
Fig. 1 Battery Reference Voltage
v
?
Battery
Reference
Voltage
Positive Probe
to BL+
Negative Probe
to BL-
! !
ELECTRICAL SYSTEM AND BATTERY CHARGER