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Old 07-27-2008, 10:09 AM   #1
blu
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Cushman
 
Join Date: Jul 2008
Location: Nebraska
Posts: 4
Default Wiring Problem on my Cushman

The problem: 3 wires needed replaced. My partner remove all three wires, went to the store to buy new wire and connectors, forgot what went where.
This is a mid 60’s Electric Cushman Golfster, 36 Volt Model 732 (not positive but pretty sure on model and year)

I drew up a diagram to try to illustrate what I’m trying to explain.



Wires that are being replaced: top and bottom wires on ignition switch. Top and bottom wires on micro switch. Wire on solenoid.
I know that one wire from the ignition goes to the neg of battery. Question, would this be the top terminal of the ignition to the battery?
I know the other terminal of the ignition goes to the micro switch. Question, bottom terminal or top of micro switch?
The third wire came off the solenoid to the micro switch. Question, does this wire go to the top or bottom terminal of the micro switch?

I hope someone here can help but even if not, I love the forum. Thanks
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Old 07-27-2008, 12:34 PM   #2
blu
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Cushman
 
Join Date: Jul 2008
Location: Nebraska
Posts: 4
Default Re: Wiring Problem on my Cushman

OK, I found the wiring diagram for my Cushman and got her going again.
With this old of a cart I'm sure I'll be back with more problems before long but this one seems to be solved.
Thanks, Blu

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Old 07-27-2008, 01:00 PM   #3
scottyb
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Location: Southern California
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Default Re: Wiring Problem on my Cushman

Glad to hear that. Luckily the older carts are pretty simple.
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Old 03-29-2014, 01:23 PM   #4
sgtstryker
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Join Date: Mar 2014
Location: Chapman, Nebraska
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Default Re: Wiring Problem on my Cushman

Hey where did you find the wiring diagram that you were looking for? I now have a cart like yours that has a couple of wires that were not hooked up after new batteries were put in. Looking for any kind of help.
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Old 03-30-2014, 06:15 AM   #5
Stevegrmich
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Location: West Michigan
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Default Re: Wiring Problem on my Cushman

. . does this help? . . .

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Old 03-30-2014, 07:43 AM   #6
Big Rock
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Join Date: Sep 2013
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Default Re: Wiring Problem on my Cushman

What a coincidence! At 5am I was laying awake trying to figure out a problem with our 1999 Cushman 797009 48 volt Hawk that I bought for use @ our campground. It's a low hour unit and all the wiring is in good shape and not all butchered up.

Here's a quick summary.
-Bought it not operating, batteries junk
-Labeled wires/cables when disconnecting
-Wire wheeled all terminals on cables
-Installed new batteries and tested on stands, forward and reverse ok
-Continued other work, testing periodically seemed fine
-I left the key and battery switch in the "on" position for about 30 min.
and smelled a burning smell, no more anything! Nothing (clicking) from coil
contactor and no light on PMC controller (it used to blink @ a constant). Although battery strength meter
on dash still reads (full charge) and of course 12v items still work
-There's a resistor (I presume) between the two large post on the coil
contactor that's getting hot and giving off the burning smell
-Seat switch unplugged, doesn't seem to mater if the wires are jumped
together or left open
-I did a continuity test of key switch and the wires from it to their final
location and they seem fine

Questions:
-Does anyone have a wiring diagram?
-If the coil contactor is bad would that make it so the light on the PMC
wouldn't be on?

I restore classic cars (AMC's) and have 2 (36v) Yamaha carts and a lot of heavy equipment so I have a pretty good understanding of things in general but not specific
to this cart.

Thanks, Rick
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Old 03-30-2014, 06:29 PM   #7
Big Rock
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Default Re: Wiring Problem on my Cushman

12141519manual.pdf

If this works it may help someone.
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