2008 Tomberlin Emerge hall effect senor issue

[ojo]

I try to explain (as far as i know): the Ezgo ITS is a 2 wire sensor. Red + green wire to the switch, black + white to the sensor. This 2 wire sensor was your old one in the Tomberlin. But there was an additional small electronic board attached.
The new style sensor you now have, is a 3 wire sensor with the electronic inside and so it's different!
The whole accelerator assembly of the Tomberlin is an Ezgo part, except the sensor. The wiring of an Ezgo will be different also.

I guess the culprit is the wiring of your sensor or microswitch, we'll see.

[Jhammer]

Alright sorry for the delay had a family emergency over the weekend. So here are the photos

[ojo]

Sorry to hear, i'm hoping the family is ok...!

I've just compared your wiring and it's wrong on the sensor ( check out the picture i've sent )
From left to right you should have:
red > positive (48v)
black > negative
blue > wiper signal (0-5v)

Red and green on the microswitch is different, but that doesn't matter.

The gap between the plunger and the sensor seems a bit too tall ( with full pedal, the plunger should enter the sensor up to the end ), a question of alignment.

Correct the wiring on the sensor and report back

[Jhammer]

Quick question on the plunger, when you say to tall what do you mean? Do you mean that the tip of the plunger is to close or to far from the hole in the hall effect sensor?

[ojo]

Looks a bit far. Check the (Ezgo) alignment instructions attached. Gap can be measured with a 17/64" drill.

[Jhammer]

So tonight I will adjust the plunger and see what the outcome is. So I have some connectors that are not plugged into anything that I can't find what are or where they go. Also, I have more female connectors than males so, in essence I have more connectors than plugs. I have attached photos of the connectors any ideas why they aren't connected besides someone unplugging them and never reconnecting them?

[ojo]

Absolutely no idea with the connectors. Yours is a E4 and is different to the E2 i've had. Check out evtechnicalservices.com ( site sponsor ) for support.

[Jhammer]

Okay so thank you for your well wishes for my family everything is great. So here's the current state of things. I swapped the wires on the Hall effect sensor and adjusted the plunger so that the plunger is now flush with the back of the hall effect sensor when the pedal is pressed all the way down. Unfortunately no the movement of the motor so we are still dead in the water. I went ahead and tested the motor this last weekend and it turned under 12volt power just fine no noises just quiet rotation. I have not checked pin 17 on the controller harness yet to see if I'm still getting 48v when the pedal is pressed all the way down instead of 0 volts. I feel like the only thing that can be wrong is the controller is bad. I have tested it with the diagnostic checklist and only pin 17 came back as an error I imagine a failure of a controller would be vast not just on pin imn my opionon but yeah here we are.

[ojo]

Ok, motor tested and running... that's good to know!
But i'm not sure, you're expecting the correct values when measuring?
The red wire on the sensor should show 48v. When pedal is pressed, the microswitch should click and there should be 48v on the green wire of the switch. While pressing the pedal slowly, the voltage on the blue wire of the sensor should increase from .5 to 5v!

When measuring on the controller side:
Pin 3 (from footswitch) with pedal up > 0v, pedal pressed > 48v
Pin 7 ( sensor signal ) with pedal up > .5v, pedal pressed > up to 5v

[ojo]

Oh, i've forgot p 17,
Pin 17 (to solenoid) with pedal up > pack voltage 48v, pedal pressed > 0v