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Unread 07-05-2010, 02:12 PM   #1
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Default 97 TXT Forward Reverse Switch

My forward/reverse switch burned up again. I have heavy duty bars in the cam but the 4 studs on the mounting plate get hot and melt the mounting plate. The plate seems to be some type of bakelite material. This is the third one in less than a year! Any suggestions on upgrades? I upgraded to 4 gauge wires after the last one burned up.
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Unread 07-05-2010, 06:26 PM   #2
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Default Re: 97 TXT Forward Reverse Switch

Can you describe your system? What other upgrades have been done to the cart?
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Unread 07-05-2010, 06:52 PM   #3
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Default Re: 97 TXT Forward Reverse Switch

I've got a 97 TXT 36 volt, non-DCS cart. It has been lifted and has off-road tires. All the wires have been replaced with 4 gauge. The cart has a 350 amp controller and new 36volt solenoid. The round part of the F/R switch (the part that rotates) has heavy duty conductor bars installed.

The problem I'm having is that the studs that the motor wires attach to on the large bakelite (black plastic) plate get hot and melt the plate. This causes them the studs to sink into the plate (because the springs on the part that rotates push on the studs). Once the stud sinks into the plate it is impossible to rotate the switch from forward to reverse. Hopefully, that helps:)
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Unread 07-05-2010, 06:59 PM   #4
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Default Re: 97 TXT Forward Reverse Switch

That helped alot. I am amazed that at 350 amps you are having this issue, however, it can happen. When you upgraded to the heavy bars, did you replace the copper studs as well? Everytime I do a heavy duty cart I remove the F&R assembly and replace it with a pair of 6 pole WR HD solenoids. Hopefully Scotty or someone else comes along and has an idea for you. The only thing I can think of off the top of my head is that the copper studs aren't heavy duty and therefore are allowing excess resistance.
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Unread 07-05-2010, 07:45 PM   #5
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Default Re: 97 TXT Forward Reverse Switch

from what i have read' it is hard to align all the parts in a do it your self copper plate upgrade. maybe buy a complete unit?

rabbit, can you expound on the two solenoid set up? i just use one white h.d. . tthx jim
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Unread 07-05-2010, 10:12 PM   #6
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Default Re: 97 TXT Forward Reverse Switch

I don't have my drawings in front of me. I will make a post tomorrow night regarding the way to wire them up. It's fairly simple and eliminates the need for a traditional F&R assembly.
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Unread 07-05-2010, 11:06 PM   #7
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Default Re: 97 TXT Forward Reverse Switch

Rabbit. I'm thinking 350a and stock motor may not be enough push for the big tires off road ... The extreme load on the stock motor may be causing the heat .... Try more voltage
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Unread 07-05-2010, 11:32 PM   #8
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Default Re: 97 TXT Forward Reverse Switch

Also, the lugs on the cables may not be making good contact or have high internal resistance since it keeps happening on the same terminals.
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Unread 07-06-2010, 12:09 AM   #9
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Default Re: 97 TXT Forward Reverse Switch

Quote:
Originally Posted by scottyb View Post
Rabbit. I'm thinking 350a and stock motor may not be enough push for the big tires off road ... The extreme load on the stock motor may be causing the heat .... Try more voltage
I considered that and of course it is gonna break at the weakest point. In this case the "suface" connection of the F&R. I took into consideration though that the factory installs 350 AMP Curtis controllers on their 6 and 8 passenger vehicles which in theory should have a heavier draw than a 2 passenger lifted cart, so I went with the idea that the "studs" on the F&R, being a copper alloy, were the bigger issue. Of course I could be completely off base and I would actually reccommend he replace the controller with a 400 AMP (and as you suggested, convert to 48 volt) but as a short term fix (until he has available funds), doing a conversion to the solenoid F&R would solve his problem (and yes, eventually he would have to replace the 2 WR HD 6 pole solenoids with 48v ones, but that shouldn't be an issue for awhile).
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