lifted club cars - lifted ezgo
Home FAQDonate Who's Online
Go Back   Buggies Gone Wild Golf Cart Forum > Golf Cart Repair and Troubleshooting > Electric EZGO
Electric EZGO Electric EZ GO Marathon, Medalist, TXT and RXV.



Post New Thread  Reply
 
Thread Tools Display Modes
Old 07-05-2010, 01:12 PM   #1
m_l_chandler
Not Yet Wild
 
Join Date: Dec 2009
Posts: 8
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.
m_l_chandler is offline   Reply With Quote
Alt Today
BGW

Golf car forum Sponsored Links

__________________
This advertising will not be shown in this way to registered members.
Register your free account today and become a member on Buggies Gone Wild Golf Cart Forum
   
Old 07-05-2010, 05:26 PM   #2
rabbitreborn
Gone Wild
 
rabbitreborn's Avatar
E-Z-GO
 
Join Date: Jun 2010
Location: Central Florida
Posts: 2,757
Default Re: 97 TXT Forward Reverse Switch

Can you describe your system? What other upgrades have been done to the cart?
rabbitreborn is offline   Reply With Quote
Old 07-05-2010, 05:52 PM   #3
m_l_chandler
Not Yet Wild
 
Join Date: Dec 2009
Posts: 8
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:)
m_l_chandler is offline   Reply With Quote
Old 07-05-2010, 05:59 PM   #4
rabbitreborn
Gone Wild
 
rabbitreborn's Avatar
E-Z-GO
 
Join Date: Jun 2010
Location: Central Florida
Posts: 2,757
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.
rabbitreborn is offline   Reply With Quote
Old 07-05-2010, 06:45 PM   #5
madoc1
no clue
 
madoc1's Avatar
E-Z-GO
 
Join Date: Sep 2009
Location: spicewood, texas
Posts: 3,308
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
madoc1 is offline   Reply With Quote
Old 07-05-2010, 09:12 PM   #6
rabbitreborn
Gone Wild
 
rabbitreborn's Avatar
E-Z-GO
 
Join Date: Jun 2010
Location: Central Florida
Posts: 2,757
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.
rabbitreborn is offline   Reply With Quote
Old 07-05-2010, 10:06 PM   #7
scottyb
Happy Carting
 
scottyb's Avatar
E-Z-GO
 
Join Date: Dec 2007
Location: Southern California
Posts: 73,358
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
scottyb is offline   Reply With Quote
Old 07-05-2010, 10:32 PM   #8
gornoman
Stay thirsty my friends!
 
gornoman's Avatar
Mixed Breed
 
Join Date: Jan 2007
Location: Suburban Chicago
Posts: 24,283
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.
gornoman is offline   Reply With Quote
Old 07-05-2010, 11:09 PM   #9
rabbitreborn
Gone Wild
 
rabbitreborn's Avatar
E-Z-GO
 
Join Date: Jun 2010
Location: Central Florida
Posts: 2,757
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).
rabbitreborn is offline   Reply With Quote
Reply
Go Back   Buggies Gone Wild Golf Cart Forum > Golf Cart Repair and Troubleshooting > Electric EZGO


Thread Tools
Display Modes


Similar Threads
Thread Forum
forward/reverse switch change to toggle switch Electric Club Car
Forward Reverse switch limit switch Electric Club Car
Do I need an HD Forward and Reverse Switch? Electric Club Car
Forward Reverse switch melted on forward...have question about replacement part Electric Club Car
Forward / reverse switch. Electric Club Car


All times are GMT -5. The time now is 01:30 PM.


Club Car Electric | EZGO Electric | Lifted Golf Carts | Gas EZGO | Used Golf Carts and Parts

Powered by vBulletin® Version 3.8.9
Copyright ©2000 - 2024, vBulletin Solutions, Inc.
This Website and forum is the property of Buggiesgonewild.com. No material may be taken or duplicated in part or full without prior written consent of the owners of buggiesgonewild.com. © 2006-2017 Buggiesgonewild.com. All rights reserved.