Keep burning up "hd" f&r switches

Luckyjayb

I keep burning up non Scotty b hd f&r switches and I'm starting to think the culprit could be bad wiring. It has a 4 gauge set up but 2 gauge soon. It has a alltrax nivel 485 controller 3 blade and it seems to keep burning the bottom stud on the f&r switch. It's a 2008 EZGO TXT series cart and does have good pack voltage at 38.3.
Thanks in advance for all the help

BGW

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gornoman

I think you nailed it already.

scottyb

400 amp controller, big tires? rear seat? hilly terrain? motor upgrade?
There is a lot more info we need to really help you decide if a better rotary switch or a reversing contactor is needed.

Luckyjayb

It is lifted with bigger tires, rear seat (seldom used), stock motor but rewound by previous owner. I know I need the Scotty b hunting buggy package but I think the wires are hooked up wrong by the previous owner. It's a 3 blade controller and the blade all the way to the left (looking from the front) had one 4 gauge wire going to the solenoid and the other going to the bottom lug of the f&r switch

Luckyjayb

Here are a few pictures.

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Luckyjayb

Looking at some of the wiring diagrams, is what leads me to think it could be wired incorrectly. I'm not wanting to order the Scotty b reverse contactor package and fry it if it was wired incorrectly. I figured the best source was to ask the best experts I know....alll of YALL on the forum

JohnnieB

There are more than one correct way to wire the high current contacts of a F/R switch and if the cart goes forwards when the lever is in the F position and goes backwards in the R position with the beeper sound and 1/2 speed reverse engaged (if desired), than it is wired in one of the correct ways.

The controller is also wired correctly, as is the solenoid.

If the bottom stud on the F/R assembly is getting hot, the problem is most likely the cable on it is bad (Bad crimp or corroded) or the cam isn't rotating all the way to the mechanical stop, so the high current contacts are not being fully engaged.


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Also, if that is a stock solenoid, it needs to be upgraded to at least a 200A unit.

Sir Nuke

Since you already stated that you are going to get a set of 2 ga. cables, you need to order a set from scotty, which comes with a great wiring diagram specifically for the cables. And buy the TRUE HD F&R Switch at the same time....they you will be all set!

Luckyjayb

Ok thats good to know. It had me worried. The cable is fine and isn't corroded or frayed.

DIRTPIT HC

If you can, go ahead and get the reversing contractor from Scotty.