Key Switch issue with TXT

[dcdon]

OK, helping a buddy with a cart came across this weird problem. I believe it is probably a mid 2000's TXT cart. Cart was working fine, lights were not working, so the switch panel was removed to check the rear wiring and in this process some of the wires came off the switch. After researching how they should go back on, we have placed the wires in the right spot, but cannot make it work. It seems that positive voltage should come in on the blue wire to the key switch and then leave on the green wire. Well, we never see any voltage on the blue wire, so i would think that is the problem.

We found the following explanation of wires. The voltage was tested and it is full 48v at reed switch and on wire running from reed switch and charger port to microswitch on f/r switch, but no voltage coming off of blue wire that leaves there. Is that a correct line of thinking? Could the microswitch be bad? It was all working fine when it was pulled up into shop to diagnose lighting , so is there a fuse that could have blown is some wire grounded out or something?


Txt solenoid activation
power starts on the white wire on the 36+ of the battery pack.
Power travels to the charger receptacle, goes through a reed switch inside the receptacle and comes out on the red 12 gauge red wire. ( check for power here, 1st!)
the red wire travels back through the loom to the forward and reverse switch where it attaches to a micro.
The other side of that micro has a blue wire attached that runs under the cart to the front and arrives at the keyswitch.
The keyswitch then transfers power to a green wire which returns to the area of the forward and reverse switch.
The power then goes through a 4 pin molex connector and travels to the "pedal box" (located under the floorboard of the car) where it goes through a micro and comes out on another red wire.
That red wire comes back up to the controller/f&r area where it once again goes through the 4 pin molex connector and continues on to the small post of the solenoid.


I am attaching some photos also. Thanks for your help.

[JohnnieB]

The N.O. contacts in MS-2 on F/R switch assembly aren't closing.
Could be a bad microswitch, the F/R cam not rotating fully to the mechanical stops or there is debris in the indentations MS-2's roller arm is supposed to drop into.

The F/R assembly shown is for an earlier cart, but indentations on cam are the same.

[dcdon]

JohnnieB. Thanksn those diagrams, and your explantion helps.

So isn't it odd that the cart was working just find before he opened up the key switch to check the light wiring? I wonder if that blue cable could have accidentally grounded and burned up that microswitch or something. Anyone ever heard of that?

also, I am looking now at where to buy these microswitches. anyone know the right one and place off the top of your head?

[Sir Nuke]

well for starters, ensure you buy the right one, (DUH lol) and one easy way to make sure you do, is take the old one off, and most likely you will find the P/N right on it.

as far as were, there are a lot of our sponsors/vendors on that site that can get you one. There is a link at the top of the page.....where you will find links to their websites. or you could go directly to shopezgo.com

[JohnnieB]

Originally Posted by dcdon

JohnnieB. Thanksn those diagrams, and your explantion helps.

So isn't it odd that the cart was working just find before he opened up the key switch to check the light wiring? I wonder if that blue cable could have accidentally grounded and burned up that microswitch or something. Anyone ever heard of that?

also, I am looking now at where to buy these microswitches. anyone know the right one and place off the top of your head?

That will wipe out a microswitch.

Always disconnect the battery pack before working in the wiring.

Here's a link to BGW site sponsors: http://www.buggiesgonewild.com/site-sponsors.php

[dcdon]

You guys are geniuses.. it does appear to be the microswitch, the other one was fine so it was we jumped a wire over (for testing purposes only... well , mostly) and it runs fine now. Picking up a new microswitch tomorrow.

[JohnnieB]

Glad to hear you found the problem.

[yurtle]

Jumpers have their place, but they can also cause sparks where you don't want them.