HD f/r switch cracked and burned

[mark38090]

I have a 2008 EZ-Go txt series cart that I use daily for work. I pull a trailer and deliver drinks and such inside a prison where gas is not allowed. The f/r reverse switch was replaced Nov 2012 with a heavy duty switch at a cost of $508 and now it looks as though it is fried again. What causes this and can the plate be replace without having to replace entire switch?

[scottyb]

From your description I'm guessing you do a lot of slow driving with a pretty good load. I'm not surprised by your pictures. A stock rotary style switch is not the best bet for this application. Consider converting over to a reversing contactor set up for more reliable operation.

Click the link below for more info:
Reversing Contactor conversion kits

[simple man]

I may be wrong, but that looks like a stock F-R switch to me.

[sportcoupe]

Originally Posted by simple man

I may be wrong, but that looks like a stock F-R switch to me.

He didn't post the HD portion which is the cam button with thicker buss bars. I believe the plate pictured is same on all versions.

[DaveTM]

That looks painfully familiar to me.

Here's what mine looked like about a month ago:

But....that's the past. I now have installed the "ScottyB" Super Duty Reversing Contactor!! (The Super Duty is "more heavy" duty than his "heavy duty" contactor.) Now I don't get any more heat!!! Worth the upgrade.

Dave

[mark38090]

Is it possible to bypass the f/r switch until I can get replacement? If I can just get forward i'm good, my inmates can push the cart backwards if needed.

[JohnnieB]

Originally Posted by mark38090

Is it possible to bypass the f/r switch until I can get replacement? If I can just get forward i'm good, my inmates can push the cart backwards if needed.

The F/R switch is basically a DPDT switch. Figure out which of the four cables are connected together when F/R is in forward and bolt them together.

On the attached schematic, it appears that the cables going to A & D would be connected together and the cables going to B & C would be connected together, but your cart might be wired differently.

The F/R switch will have to be assembled and in the F position, or MS-2 won't be closed.

[mark38090]

Tried but no success. I'm gonna try some more testing tomorrow. Might take a month for state to buy f/r switch...

[mark38090]

Originally Posted by JohnnieB

The F/R switch is basically a DPDT switch. Figure out which of the four cables are connected together when F/R is in forward and bolt them together.

On the attached schematic, it appears that the cables going to A & D would be connected together and the cables going to B & C would be connected together, but your cart might be wired differently.

The F/R switch will have to be assembled and in the F position, or MS-2 won't be closed.

On your diagram, is the "a" terminal on the top of the plate? Then do they go clockwise? I'm trying to talk them into buying the reversing contactor setup that is suggested above but its extremely hard for the state to purchase from internet. In the mean time I'm doing a ton of walking...

[JohnnieB]

The "A" terminal is on the bottom, and they are counted clockwise.

The same F/R assembly was used on earlier carts and it hung down from the seat frame instead of being bottom mounted. The labeling stayed the same, so "A" is on the bottom when the assembly is bottom mounted.

Here is a drawing of the F/R assembly. It is show in the hanging position, so turn the picture upside down to see the way the terminals are labeled in your cart.