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Electric EZGO Electric EZ GO Marathon, Medalist, TXT and RXV.



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Old 05-18-2015, 11:02 PM   #1
swaynelee
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E-Z-GO
 
Join Date: Apr 2015
Location: Louisiana
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Default Reversing Contactor Install Pictures

Installed a new reversing contactor from scottyB today, and just wanted to post some pictures so people could see what is involved in installing one of these thing. This may be a long post but I hope it helps somebody out who is doing this for the first time like I did. The instructions that came from cartsunlmited.net are really good but nothing like a few pictures to help out.

So here is the cart from the start. It is a 1994 EZGO Marathon 36V. One of the reasons for installing the Reversing Contactor is the wife really hated the shifter knob I was using.
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Old 05-18-2015, 11:15 PM   #2
swaynelee
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Join Date: Apr 2015
Location: Louisiana
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Default Re: Reversing Contactor Install Pictures

First thing was to email ScottyB at Carts Unlimited with the info on my cart to make sure I was ordering the correct kit. ScottyB replied to my email on the same day, and I placed my order on a Monday morning. Within a few minutes of placing my order I received a tracking number for the three day shipping. On Thursday the kit arrived and I opened everything up to check that all the parts were included for the install. Everything was in the box which had been packaged very well so nothing was damaged,
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Old 05-18-2015, 11:25 PM   #3
swaynelee
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Default Re: Reversing Contactor Install Pictures

After reading the instructions a couple of times, I took a lot of pictures of how the cart was wired so if something went wrong I could undo the install and put the cart back together. I also printed out the wiring diagram for my cart which I got from the BGW site. Next thing was to get rid of the old shift handle and then disconnect the batteries. Now I labeled all the main battery wires on the old F&R switch with some painters tape numbering the cables per their location on the old switch.
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Old 05-18-2015, 11:29 PM   #4
swaynelee
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Default Re: Reversing Contactor Install Pictures

Next was removing the old F&R switch.
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Old 05-18-2015, 11:37 PM   #5
swaynelee
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Default Re: Reversing Contactor Install Pictures

Installing the new contactor was the only real problem I had because the mounting bracket that my old switch used was to short which held the new contactor above the frame of the cart not allowing the seat to go down. A quick fix for me was to take a couple of scrap aluminum bars and make a add on to my mounting bracket which lowered the location of the contactor.
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Old 05-18-2015, 11:48 PM   #6
swaynelee
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Default Re: Reversing Contactor Install Pictures

The next step was to mount the plastic switch plate on the cart over the hole from the old F&R switch. A couple of sheet mental screws was the easy way for me to do this. Then run the three wires that you have to make from the rocker switch thru the hole to the contactor and the Location you get +36V from. I used the Potentiometer to get the +36V so that when the key switch is off so is the reversing contactor. I could of just tapped into the key switch but it was easier to get it from the potentiometer for me. The only thing I didn't get a picture of was running the wires from the rocker switch thru the hole to the contactor.
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Old 05-18-2015, 11:54 PM   #7
swaynelee
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Default Re: Reversing Contactor Install Pictures

Next thing was to reconnect the labeled wires to the new contactor and check all the wiring before reconnecting the batteries.
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Old 05-19-2015, 12:32 AM   #8
swaynelee
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Default Re: Reversing Contactor Install Pictures

Well that's all there was to it. Took me about eight hours from opening the box to making test runs with the new switch installed. Yes it took me way to long to install it but I have a lot of excuses for why it took so long. First this is my first cart and the only thing I know about cart's is what I learned off this site. The cart was a mess when I purchased it cheap from a neighbor who got a new one. The only other thing I have done to the cart was replace the potentiometer that was bad on it.

While I was installing the reversing contactor I also installed a new control board in my Total Charge 3 battery charger and fixed the charging plug on the cart that was not working.

I also had the neighbor's 12 year old son crawling all over the cart all day trying to help me fix it. It kept him off his game box all day and out of his mothers hair I guess, but it did drive me a little crazy at times. On top of all that I have a broken leg so hopping around the cart all day added to the amount of time it took to do the work.

I also live in south Louisiana and had to take some time out to do this too. I know some of you Yankees up north think this is fish bait, but down here we call this GOOD EAT'S........ That's right hot boiled crawfish.....
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Old 05-19-2015, 12:50 AM   #9
swaynelee
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Default Re: Reversing Contactor Install Pictures

O.K. so here's the bottom line on cost.

Switch kit from cartsunlimited.net $216.00 including the shipping.

New Multi-meter just because I wanted my own $54.00.

Two spools of 12 ga wire $14.00.

A cheap crimping tool kit with connectors $18.00.

Never hearing my wife complain about using a pair of vice-grips for a shift lever again. PRICELESS !!!!!!

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Old 05-19-2015, 02:55 AM   #10
tag50
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Default Re: Reversing Contactor Install Pictures

Well done. Thank you


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