2089 model EZGO Reverse is random

k54fjb

Hello I am trying to help friend with an 1989 EZGO mararthon cart. It is electric with resistor control. It quit working in reverse ( very occasionaly will work) I replaced the entire Forward/Reverse assembly and we have the same problem. I have witnessed it go into reverse a couple of times but rarely. I am sure that we have it wired the same as the old one ( have pictures) and we cleaned every connection we can find. I have found several wiring diagrams that say they are for the 89 model but have some slight differences. My main question concerns the micro switches and the correct wiring for them. The one seems to do nothing but the reverse alarm ( don't care about it) The other I assume is OK since it works in forward. It is connected to the On/Off switch with a blue wire and the yellow goes straight to the solenoid. But I have one diagram showing blue to the switch and a black wire on the NC side going to S1. DOes the reverse alarm need to be hooked up for reverse to work?
Any help or photos would be great. Thanks

BGW

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JohnnieB

Welcome to BGW!

Please post picture of 2089 cart because I doubt if I'll be around to see them since I'd be 146 years old by then.

If you trace out the solenoid activation circuit on both versions of the wiring diagrams, you'll find they are the same except for the order the switches are in.
Either version is "correct", so pick one.

There are two microswitches on F/R assembly. One has continuity between C and NC in both F(orward) and R(everse) while the other only has continuity between C and NC in R.

Does the solenoid click in both F and R?
If so, the contacts in the F/R switch are bad or misaligned.
If not, the microswitch on the F/R that should have continuity in both F and R is misaligned or bad.

k54fjb

Sorry, the manufacturers number IE model number is 2089 which is an 1989 year cart. When it will not go in reverse I do not hear the solenoid click. The weird thing is that I saw it go in reverse one time with the old F&R switch and a couple of times with the new one so I am pretty sure the wiring is OK. I have a degree in Electronics and looking at the circuit, the only parts that are different for reverse have been replaced, it is driving me buggy. No pun intended. What else can be intermittent?
Thanks for the reply

k54fjb

There is an alignment for the contact on the F&R switch?

rocknrone

Yes.
But, one other thing you can check is to turn the adjustment nut on the f/r switch about a quarter turn to make sure it is getting good contact between the lugs and the switch. When I replaced the switch cam in my f/r, I didn't tighten the nut enough, and it would only run intermittently. Took a while, but I figured out that I must not be making good enough contact because it was shifting very easy. Too easy. About a quarter turn later, I haven't slowed down since.

JohnnieB

Take a closer look at the schematic, no parts are different between F and R.
Direction of current flow through armature is different, but that's it.
Or at least that is it electrically.
The mechanically difference is the rotational angle of the F/R cam.

Since the solenoid is not clicking in R, I suspect the problem is the cam is either not rotating far enough to fully release the lever arm on MS-2, or the indentation in the circumference of the cam is filled with debris.

Here's a drawing showing the how the microswitch lever arms ought to line up with the indentations on the cam. (The drawing is for your cart specifically, but EZGO has used the same switching arrangement since the Earth was flat)

Please note that the NC contacts are used, so the microswitch lever arm has to be released to close circuit and activate solenoid.

Attached Images

F-N-R with microswitches on cam.JPG (60.5 KB, 0 views)

k54fjb

Thanks Johnnie B that diagram is very helpful. I have some schematics referencing MS1 and some saying MS4 and that is good for clarifying that. Yes I know the electrical components are the same ( minus the reverse alarm circuit ) that is why it is so confusing as to why it is always reverse that has the issue. Thanks for all the input. I am slowing building a useful information manual from all the information I get.

k54fjb

Looks to me like the 2 MS switches on my friends cart are wired opposite. I will check next time I get out there. Thanks again to everyone for input.

53jimc

Yep, that should operate more like a hoverboard or speeder. I want one. (jk)

k54fjb

Eureka! I have found it! JohnnieB you hit it on the head. The microswitch MS2 was misadjusted slightly from the factory ( or the detent on the cam was not deep enough ). The switch would work in forward since it is a different physical notch on the cam. I loosened the 2 screws that hold the switch and moved it farther out from the cam and reverse works perfect. Thanks for all your input.
My friend has a lovely garden and water features in his backyard and his elderly mother enjoys seeing them but has trouble walking. The cart is her only mode of enjoying the outdoors and since it would not go into reverse there were places she could not go.
God bless you all for sharing your knowledge and experience.