EZGO F&R switch burning up

[robbiescd]

Been working on a 2005 (?) 36v electric golf cart. Earlier in the year, the cart was brought to me with a no run issue. I’m mainly a gas guy, but I’ve messed around with electric carts. Upon inspection, I noticed the F&R switch had an electrical burn on it. Ordered a new switch, installed and all ok. Last week, the customer called saying it wasn’t running again. I definitely didn’t think it would be the F&R switch, so I began looking at the batteries and stuff. The batteries were almost dry. Put 2 1/2 gallons of water in all the batteries, put on charge, and the battery indicator showed that batteries were fully charged.

To make a long story short, I ended up checking voltage in and out of F&R switch. The bottom pole (without pedal being pressed)had voltage. When moving to forward or reverse, no power was read on the connections going to motor. Disassembled switch and found that there was no continuity from the main power pole to the motor poles. Disassembled switch further, and noticed bottom pole (the copper contact) had melted into the recessed area and the pole that rolls over it to make contact was not making good contact with the recessed copper pole. Hope this makes sense. I’m trying to be as detailed as possible!

I noticed that when the pedal is not pressed, I am getting voltage (37v?) on both large poles of the selonoid. Wire from control side goes to pole to controller (B+). Then a wire from B+ to the bottom pole on F&R switch. So the switch has power going to it when ever the key is turned on.

Why is the F&R burning up? Second one in 6 months. I did rig up a plastic washer to go under the copper post so that it will make contact, but haven’t had time to install back in cart to see if it fixed the problem. I’m pretty confident that is the issue though. Just concerned over F&R switches going bad.

By the way, the switch isn’t really “totally burned up”. I went to remove the post that power is running to. Normally they just drop out for easy replacement. I had to hit it with a hammer to get it out. The plastic had melted around the threads on the pole. That’s what I mean by burned.

Sorry for long post......just trying to be as detailed as possible.