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-   -   Heavy Duty F/R Switch Cam Install (https://www.buggiesgonewild.com/showthread.php?t=39013)

gornoman 09-22-2010 06:47 PM

Heavy Duty F/R Switch Cam Install
 
HD Switch Cam from Scottyb and Carts Unlimited. Why do it the hard way? Just replace the whole cam and be done with it!

New and old cams:
http://i92.photobucket.com/albums/l2.../092210006.jpg

Remove actuator lever:
http://i92.photobucket.com/albums/l2.../092210005.jpg

Remove shaft and old cam to reveal existing backplate:
http://i92.photobucket.com/albums/l2.../092210007.jpg

Clean up the backplate:
http://i92.photobucket.com/albums/l2.../092210008.jpg

Lube the shaft and copper lugs with dielectric grease:
http://i92.photobucket.com/albums/l2.../092210012.jpg

Reassemble and you're done! The instructions that come with the HD Cam are well written, and the job is quite easy. 30 minutes, tops.

gornoman 09-22-2010 08:09 PM

Re: Heavy Duty F/R Switch Cam Install
 
There was an issue however. Since my cart is 13 years old I requested new Copper bolts for the baseplate. Figured there would be plenty of wear, so why not replace them.

Old and new:
http://i92.photobucket.com/albums/l2.../092210009.jpg

When these were installed, the added head thickness of the new bolts added onto the added head thickness of the bolts in the new cam pushed the cam away from the baseplate enough for the metal strap on the new cam to bypass the stops on the baseplate. This allowed the actuator to extend past the normal position and start to spin over the other side.
http://i92.photobucket.com/albums/l2.../092210014.jpg

Solution for me was to reinstall the old copper bolts to close up the gap, and all is fine. The old bolts looked fine after a dressed them out on the wire wheel.

scottyb 09-22-2010 08:30 PM

Re: Heavy Duty F/R Switch Cam Install
 
Glad to hear it all went well. The Switch cam has new stud/lugs in it & the super thick buss bars, so I guess it was just too much copper in there? I guess you could grind the lugs down or lengthen the stop but .... Like you, I have not seen anything major in terms of wear on the stock lugs in the TxT carts yet.

gornoman 09-22-2010 08:34 PM

Re: Heavy Duty F/R Switch Cam Install
 
Now if you could just supply some taller stops......

It appears they are replaceable?

scottyb 09-22-2010 09:50 PM

Re: Heavy Duty F/R Switch Cam Install
 
A look at the stops shows they unbolt from the backside. They could be raised with a washer under them....

gornoman 09-22-2010 10:29 PM

Re: Heavy Duty F/R Switch Cam Install
 
Heck of a good idea, scottyb. I'll look into that next week. Can't tear it down now, I gotta race to attend!

scottyb 09-22-2010 11:07 PM

Re: Heavy Duty F/R Switch Cam Install
 
I grabbed an old base plate out of the salvage bin. It had a lock washer on the backside. 7/16 wrench remove the stop, move the lock washer from the back to front; under the stop, and replace the bolt ~ wha la :wink:

ChevyRacing75 09-23-2010 08:01 AM

Re: Heavy Duty F/R Switch Cam Install
 
Looks like it went smoothly for you :thumbup: Scottyb makes it easy :mrgreen:

gornoman 09-23-2010 08:57 AM

Re: Heavy Duty F/R Switch Cam Install
 
Yeah, it was quite easy. My 48v conversion is now complete. It only took me 3 years! LOL!

scottyb 09-23-2010 09:22 AM

Re: Heavy Duty F/R Switch Cam Install
 
Gornoman has made a couple of suggestions for improvement in the instruction sheet, so now, even a caveman can do it :wink:

Actually, he hinted I should translate it into Chinese and then back to English so it reads like so many of the instruction sheets we get these days.......:lhmo:

SHAWN DAVIS 09-23-2010 10:00 AM

Re: Heavy Duty F/R Switch Cam Install
 
Are all the H-D switches the same? Is there a preferred one?
and what makes one heavy duty?

gornoman 09-23-2010 10:14 AM

Re: Heavy Duty F/R Switch Cam Install
 
Quote:

Originally Posted by SHAWN DAVIS (Post 459701)
Are all the H-D switches the same? Is there a preferred one?
and what makes one heavy duty?

Shawn, the parts that make one of these "heavy duty" are the buss bars:
http://i92.photobucket.com/albums/l2.../092210012.jpg
The buss bars are the flat copper strips between the copper bolts. The buss bars are the weak link in an EZ-Go electric drivetrain. The stock units are thin and can heat up on modified carts under load, damaging themselves as well as the surrounding hardware.
http://i92.photobucket.com/albums/l2.../092210006.jpg
You can see the difference in thickness here.

ab46501 09-23-2010 10:20 AM

Re: Heavy Duty F/R Switch Cam Install
 
I had the same problem with the stops when I upgraded my cam and put new bolts on the back plate. The stops are just square nuts. The solution for me was to go to Lowes, probably any good hardware store would do. They have a coupling nut that is twice as long/tall as the square one and will give you the extra length you need. Easy to switch out.
[IMG]http://www.buggiesgonewild.com/membe...ut-din6334.jpg[/IMG]

SHAWN DAVIS 09-23-2010 10:21 AM

Re: Heavy Duty F/R Switch Cam Install
 
Gotcha, thanks!

mauistardog 09-23-2010 01:50 PM

Re: Heavy Duty F/R Switch Cam Install
 
Thanks for the tips on the stop, I picked up the same cam from scott. Really nice work and easy to install. Will move the washers that scott talked about from my old one. The good thing is that people can just take your cart, because only you know exactly where the right point of contact is. It is kinda like a built in security. :mrgreen:

joe

dvmartin 09-23-2010 04:19 PM

Re: Heavy Duty F/R Switch Cam Install
 
What is the lubricant that can be seen on the new part? Is it a have to or just nice. The carts that I maintain do not have any kind of lubricant and seem to work fine.

pggroves 09-23-2010 04:41 PM

Re: Heavy Duty F/R Switch Cam Install
 
Quote:

Originally Posted by gornoman (Post 459705)
Shawn, the parts that make one of these "heavy duty" are the buss bars:
http://i92.photobucket.com/albums/l2.../092210012.jpg
The buss bars are the flat copper strips between the copper bolts. The buss bars are the weak link in an EZ-Go electric drivetrain. The stock units are thin and can heat up on modified carts under load, damaging themselves as well as the surrounding hardware.
http://i92.photobucket.com/albums/l2.../092210006.jpg
You can see the difference in thickness here.

Nice buss bars boys. :shock: :lhmo:

gornoman 09-23-2010 06:57 PM

Re: Heavy Duty F/R Switch Cam Install
 
Quote:

Originally Posted by dvmartin (Post 459796)
What is the lubricant that can be seen on the new part? Is it a have to or just nice. The carts that I maintain do not have any kind of lubricant and seem to work fine.

The lube is dielectric grease. It is there to PREVENT the switch from binding, which happens so often on these assemblies as they age. Series cart owners know what I mean.

scottyb 09-23-2010 08:18 PM

Re: Heavy Duty F/R Switch Cam Install
 
Nothing but the finest Ultra-Conductive High-Heat Copper Alloy 8)
Our Engineer is top notch :thumbup:

Dave in VA 09-24-2010 07:14 AM

Re: Heavy Duty F/R Switch Cam Install
 
That's a nice looking part, Scotty. I don't know anything about sparkie carts, but it looks like the thickness of the original buss bars is marginal, at best. Or are they OK until you do upgrades? Yours looks twice as thick. Maybe someday I'll get a sparkie to play with. :mrgreen:

scottyb 01-24-2011 05:58 PM

Re: Heavy Duty F/R Switch Cam Install
 
It has been awhile and this thread needs an update.

We did have stop issues on the first cams we used... That was sorted out. The cam stop is now long enough to work with the factory stops. The Buss bars have also gone through some changes. The new alloys and design runs cooler than ever.. The directions are now Printed and Pictured for those of us who hate to read, & who doesn't?
So I'll stop typing now :lol:

scottyb 01-24-2011 06:03 PM

Re: Heavy Duty F/R Switch Cam Install
 
It has been awhile and this thread needs an update.

We did have stop issues on the first cams we used... That was sorted out. The cam stop is now long enough to work with the factory stops. The Buss bars have also gone through some changes. The new alloys and design runs cooler than ever.. The directions are now Printed and Pictured for those of us who hate to read, & who doesn't?
So I'll stop typing now :lol:


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