PCX-956 runs forward not reverse

[Dan Craig]

Hi everyone,
I have an old EZGO PCX-956. I believe it's mid-90's with a controller box vs a stack of solenoids.

Recently it stopped running all together. We dug in and found some well burned contacts in the direction switch mechanism.

We replaced the cam/dial portion of the direction switch and now we get only forward, no reverse.

We've got the thing installed in the orientation which allows forward and reverse lever to operate and stop positively against the stops in the mechanism. The micro switch seems to be actuated and operating in it's normally closed configuration and the indents in the cam seem to align with the micro switches. The new part looks and seems to operate identically to what we removed.

I've suggested we swap S1 and S2 on the motor which are the field winding and see whether we get reverse when the switch is in the forward position to help us rule out the motor.

The thing I'm most stuck on is why we're only getting one direction when the only moving part in this setup is the cam attached to the direction lever.

Anyone have other ideas? I'm not familiar enough with older EZGO carts to know what other models might have used similar direction control setups.

Thank you to anyone who has any suggestion. Right now we're open to all.
-Dan

[kgsc]

If it runs in forward motor is fine. If the solenoid is clicking when you try reverse the fnr is your issue

[Dan Craig]

Originally Posted by kgsc

If it runs in forward motor is fine. If the solenoid is clicking when you try reverse the fnr is your issue

Thanks for the quick reply kgsc - the solenoid only clicks once - when you turn the key on (if in F or R) or when you switch to F or R when the key is already on.

Is that one click abnormal?

[kgsc]

Not normally but that won’t kill your reverse. Normally won’t click until the go pedal is pushed but the 956 is new to me.

[Dan Craig]

Ok, thanks. We have various carts here which have newer controllers and they typically only click when the pedal is pushed.

This one is stumping us because the only moving part (other than the solenoid clicking) is the direction switch. Just changing the polarity on motor contacts. Should be simple...

Thanks again for the replies and thanks in advance to anyone else who has experience with an old cart like this.

[Dan Craig]

Figured it out - it was indeed the F N R switch. One of the copper studs had overheated in the past which left it's socket a little low so when we replaced the studs - that one particular stud sat a little lower and combined with a couple slightly higher studs on the cam there was no contact. A little continuity tester on the whole switch assembly revealed this to me pretty quickly. I added some thin metal shims to build the stud up a bit and adjusted the higher studs on the cam and got things making contact again when rotating the lever.

I also found the solenoid does not automatically click when you shift to F or R, or when you turn the key on, unless the switch under the accelerator linkage isn't properly secured. Now the solenoid only clicks when you depress the pedal.

Thanks again for the sounding board. Glad to have that crazy old cart operating again.

[kgsc]

Good deal