F/R Switch replacement? Overheating?

drewloker

Hello. I am trying to determine which replacement F/R switch I need to get. I am pretty sure the current sure switch is the source of the problem. So, I am trying to decide if need the exact replacement, or do I need to upgrade the switch to a heavy duty switch. Either way, I am trying to figure out what model I need...non-DCS, etc.

History of the cart:
I acquired a '95 EZGo Freedom about summer of 2017. It came with a ~3" lift and oversized tires (22x11x and had 6 Interstate 6 volt batteries that were about 5 years old that were doing ok at first, but started to show their age...and I think I let one of the batteries go unchecked on the water and killed the battery. So, I replaced the batteries last summer.

We don't use the cart a whole lot, or for very long. I don't recall the cart having over-heating issues, but at some point we noticed the smell of burning plastic, but only sometimes, but with increasing frequency. At first, I thought I just got some WD-40 on something I shouldn't have. Not sure if the smell started before or after the batteries. But, I started to investigate more into the source of the smell...and it seemed to have gotten worse. Well, it was a lot worse. Something was smoldering from either at the terminal, or slightly behind the F/R switch lower terminal. After a lot of reading, I decide that maybe the battery cables were causing excessive resistance and that when I changed out the batteries, I damaged one or more of the cables (4 gauge) to the point that the resistance had gone up. So, I changed all of the main batteries cables with zero change. I also used a spot temp reading and did a little more testing. The heat definitely seems to be coming from the switch, and only seems to build up when a load is placed...so...it doesn't heat up until I turned the switch and push the gas.

So, based on some more research, I think I may just have a bad switch. And if that is the case, do I need to go ahead and upgrade it to a heavy duty.

I am going to try to attach a gallery of images (looks like I can't) as well as some pictures and w would really appreciate any input on what switch I need to get. Thank you in advance for your time!!

https://photos.app.goo.gl/gqp2UFhqRS2weVP9A

BGW

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Sir Nuke

well first off we need to have you verify exactly which drive system, you have.




and I am guessing from you description, you most likely have a SERIES srive system, and if so I would highly recommend you get a HD F&R from cartsunlimited.net (one of our sponsors, and the best hd f&r available)

https://www.cartsunlimited.net/f---r--switches.html


Oh and btw.....Welcome to our happy little corner of the net, and to BGW. There is a BIG fridge on the back porch with anything you can think of in it...help yourself...of course only take what you can LEGALLY have. Make yourself at home on one of the big fluffy couches, kick your shoes off, put your feet up on one of the tables, yes we are allowed to do that, mom's, wives’, husbands, girlfriend’s and boyfriends here don't care....and take it easy.



oh...btw....every once in a while a food fight breaks out...so you may not want to wear nice clothes here.

Welcome!!

70oldsracer

I'm pretty sure since he said non-dcs and from his pics, it's a series cart. I'm hoping he will confirm that. I would say your fwd/rev switch is definitely bad. In the first pic of the switch you have, look at the terminal on the right, not only does the lug look bad, but you can see the switch is burnt. I believe this is the S2 cable from the motor. Also, the top terminal doesn't look too good either. I can't tell if that's discolored from rust or overheating. Again, not 100% sure, but I believe that's your A2 cable from your motor. I would get a new, HD F/R switch and change out that one motor cable. You can get the switch here:
https://www.cartsunlimited.net/f---r--switches.html It's option #3 EZ575

yurtle

If series - which it really sounds like - you do need HD or upgrade to a reversing contactor.

Andy4639

rib33024

DCS drive system came out in 94.5 and stopped in 99. And if you look at the pics, you can see that it is a series drive. The F/R is bad/Burnt up and needs to be replaced a long with some cables

orangeman6

Its a little bit more, but the contactor is worth IMHO.

https://www.cartsunlimited.net/rever...ontactors.html

Andy4639

drewloker

Thanks for the quick replies and feedback.

Orangemen6, I wish I could go that route. Looks like a nice solution. I am curious though. I tend to leave the lever switch in the middle as OFF rather than turning off the switch. Does the rocker upgrade have a center position?

Thanks!

mgray70

Yes it does! Very nice upgrade, and much easier to switch.

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