91 ezgo limit switch wire

[sunoco]

Can someone tell me where the red wire coming from the fnr limit switch goes? I can't find a diagram?

[yurtle]

Most electrical diagrams can be found in the Stickies, above.

Link here:
Owner's, Parts, and Service Manuals:
http://www.buggiesgonewild.com/elect...g-manuals.html

Are you in industrial electrical or automation? At work, these would be "limit" switches, but there, most folks refer to them as micro switches.

Correction: I keep forgetting I just retired, so make that, "at my former job..."

[JohnnieB]

That appears to be the wire that used to go to the reverse beeper.

[sunoco]

Thanks. I forgot to mention this is a solid state cart. I don't think it changes where it goes just saying

[JohnnieB]

I was wondering about those five 1K resistors on the wiper arm board. Now I understand it.
You either have a resistor cart that was converted to a controller cart, or possibly very early controller cart.
All the controller carts I've seen schematics of, used a 0-5K potentiometer rather than a series of fixed value resistors.

Basically it is a five speed cart.

However, the microswitch connections would be the same.

[rib33024]

JohnnieB


I was looking at that to, because it looks like it only has one battery cable connected to the bottom lug on the wiper board, where there should be no cable hooked up

[sunoco]

Originally Posted by yurtle

Are you in industrial electrical or automation? At work, these would be "limit" switches, but there, most folks refer to them as micro switches.

No, I just refer to them as limit switches lol

[sunoco]

I'm not sure about the wiper arm assembly. A little out of my element with an early E-Z-GO

Serial number indicated its a 91 4 wheel Marathon

Customer said it stopped one day and wouldn't charge. As you can see, the corrosion levels on everything is crazy. There were a couple cables that had completely corroded off so I replaced. There was also one that came loose from the solenoid. Once I connected it back the solenoid clicks but the cart still doesn't move.

[JohnnieB]

@ Rib

I suspect the Black wire on the bottom stud goes to the controller's throttle input and the White wire from the controller throttle input is connected to the wiper arm moved by the pedal linkage.

Looks like an inexpensive way of converting a resistor cart to a controller cart without going through the hassle of installing a pot box and figuring out the mechanical aspects of the throttle linkage.

It only has five fixed speeds rather than being continuously variable, but with some tweaking of the resistor values, you could customize those speeds to meet your needs or desires.

[JohnnieB]

Originally Posted by sunoco

I'm not sure about the wiper arm assembly. A little out of my element with an early E-Z-GO

Serial number indicated its a 91 4 wheel Marathon

Customer said it stopped one day and wouldn't charge. As you can see, the corrosion levels on everything is crazy. There were a couple cables that had completely corroded off so I replaced. There was also one that came loose from the solenoid. Once I connected it back the solenoid clicks but the cart still doesn't move.

Solenoid clicks but cart doesn't move.
Could be an open cable, connection or contact in the high current loop, or the controller isn't being told to pass amps to the motor (Throttle issues).

Connect a DVM between the B- and M- terminals on controller.
Push pedal just until solenoid clicks and you should measure FULL battery pack voltage.

If not, something is open in the high current circuit. (F/R switch contacts, bad cable, motor brushes, etc)

If you get full battery pack voltage, either the the throttle isn't telling the controller to pass amps to motor, or the controller is bad.
Also, check for pack voltage on the blue wire on the controller. That has to be present to turn controller on.

Here is a controller cart schematic. Except for the throttle setup. it should match up with your cart close enough to troubleshoot with it.