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Electric EZGO Electric EZ GO Marathon, Medalist, TXT and RXV. |
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04-02-2012, 09:23 AM | #1 |
Gone Wild
Join Date: Sep 2011
Location: Midwest
Posts: 384
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Big, exploded, labeled pic of F/R assembly?
I've looked through the stickies and have done a search and can't seem to come up with a very large, thorough picture of a F/R assembly. I have a 2006 TXT series. Just trying to figure out how it works.
My reverse works intermittently and I'm trying to fix it myself. Also, if anyone could explain how it works in simple terms, I'd appreciate it. Thanks. |
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04-02-2012, 10:38 AM | #2 |
Happy Carting
Join Date: Dec 2007
Location: Southern California
Posts: 73,358
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Re: Big, exploded, labeled pic of F/R assembly?
The F&R is a rotary switch. The main housing has 4 cable terminals and the rotary cam has 4 contacts which are paired together by buss bars. There is not a lot of 'repair' that can be done especially if the switch has gotten hot and the contacts have sunk in the plastic housing.
Some people claim they have disassembled and cleaned the contacts and got them working good but, I'm skeptical as to how long this 'fix' will last. Here is the exploded view with a few tech notes from my documents. I hope this helps. |
04-02-2012, 10:44 AM | #3 |
Techno-Nerd
Join Date: Jun 2011
Location: West Virginia
Posts: 19,654
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Re: Big, exploded, labeled pic of F/R assembly?
Attachment #1 is a drawing of the high current circuit for a generic series cart.
It shows how everything is connected in series and how the F/R switch has current flowing through the stator fields in one direction for forward and the other direction for reverse. Attachment #2 is a drawing of the cable side of an F/R switch. The four heavy cables attached to studs that go through the plastic and become the fixed (Non-Moving) high current contacts. Attachment #3 is a picture (stolen from scottyb's website) of a F/R cam, showing the heavy copper bars and contacts that complete the circuit between the fixed contacts. Attachment #4 is a drawing showing how to test the F/R switch for continuity (also from scottyb) Finally, here is scotty's page on F/R switches. http://www.cartsunlimited.net/F_R_Switch_Upgrades.html I see Scotty has posted while I was stealing stuff from his site, but I'll post anyways. |
04-02-2012, 11:23 AM | #4 |
Gone Wild
Join Date: Sep 2011
Location: Midwest
Posts: 384
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Re: Big, exploded, labeled pic of F/R assembly?
Thanks Scotty and Johnnie!
I hope I can make sense of things. Where on these pics would I apply a little dielectric grease? |
04-02-2012, 11:35 AM | #5 |
Gone Wild
Join Date: Sep 2011
Location: Midwest
Posts: 384
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Re: Big, exploded, labeled pic of F/R assembly?
So Johnnie......on the pic of the cam, when I turn the F/R knob, it turns the device on the right to line up on the device on the left in just the right positions to make it go forward to backwards? Is there a way of cleaning those contact points? Is that where dielectric grease goes?
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04-02-2012, 12:24 PM | #6 |
Gone Wild
Join Date: Feb 2010
Posts: 551
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Re: Big, exploded, labeled pic of F/R assembly?
I will post back later when I have more time and try to Help You. Don't worry it is possible to repair the Switch. I'm 15 and I did it myself.
LOL Matt |
04-02-2012, 12:25 PM | #7 | |
Techno-Nerd
Join Date: Jun 2011
Location: West Virginia
Posts: 19,654
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Re: Big, exploded, labeled pic of F/R assembly?
Quote:
2. Yes, some people have done it. I've never done it or seen it done, but having worked on high power contacts in other applications, I'm pretty sure it would only be a temporary fix. 3. Lubricate the four bumps on the cam and the four stationary contacts with it. The F/R switch is critical to good performance, so in my opinion, it would be best to go with complete Heavy Duty switch, but you might get away with just installing a Heavy Duty Cam if the stationary contacts are too badly arced or out of position due heat softening the plastic they are mounted in. The thing to remember is that total current passes through all the high current cables, batteries, controller, solenoid, F/R switch and motor equally, so the series chain is only as good as the weakest link in it. |
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04-02-2012, 02:46 PM | #8 |
Gone Wild
Join Date: Aug 2010
Location: Marion, Ohio
Posts: 1,391
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Re: Big, exploded, labeled pic of F/R assembly?
I dismantled mine and did all the rough work with steel wool and brake parts cleaner. I then put the buffing pad on the Dremel and went to work with chrome polishing compound. If it is made of copper, shine it up as best you can. Before I reassembled it, I covered everything with dielectric grease. I think my biggest problem was just the oxidation and not wear. My cart had sat outside for umpteen years after the batteries gave out collecting mildew slowly sinking into the soil from whence it arose. I dragged it out of the hole it was in with my old man's 4x4. I had lots of work to do to return it to functional status. The old gal is feeling a lot more love these days, but I'm still going to be replacing that switch in the near future.
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04-02-2012, 03:14 PM | #9 |
......................
Join Date: Apr 2009
Location: FT Lauderdale FL.
Posts: 16,416
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Re: Big, exploded, labeled pic of F/R assembly?
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04-02-2012, 03:22 PM | #10 | |
Astronautilator
Join Date: Sep 2011
Location: North Idaho
Posts: 1,494
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Re: Big, exploded, labeled pic of F/R assembly?
Quote:
The problem is getting all the contact pairs to be in 100% contact at all positions. Less contact will produce heat and heat will eventually cause failure. Pictures exploded but not labeled. Now I'm just being a smart alack |
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