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Old 09-22-2010, 06:47 PM   #1
gornoman
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Default 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:


Remove actuator lever:


Remove shaft and old cam to reveal existing backplate:


Clean up the backplate:


Lube the shaft and copper lugs with dielectric grease:


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.
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Old 09-22-2010, 08:09 PM   #2
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Default 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:


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.


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.
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Old 09-22-2010, 08:30 PM   #3
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Default 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.
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Old 09-22-2010, 08:34 PM   #4
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Default Re: Heavy Duty F/R Switch Cam Install

Now if you could just supply some taller stops......

It appears they are replaceable?
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Old 09-22-2010, 09:50 PM   #5
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Default 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....
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Old 09-22-2010, 10:29 PM   #6
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Default 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!
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Old 09-22-2010, 11:07 PM   #7
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Default 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
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Old 09-23-2010, 08:01 AM   #8
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Default Re: Heavy Duty F/R Switch Cam Install

Looks like it went smoothly for you Scottyb makes it easy
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Old 09-23-2010, 08:57 AM   #9
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Default 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!
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Old 09-23-2010, 09:22 AM   #10
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Default 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

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.......
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