switch in reverse moves cart forward

[Bluetick1955`]

I have a ezgo 16M95. Working fine yesterday. went to back out today and put in reverse and cart moved forward. pushed out and drove forward fine.

grandson rode yesterday and plugged charger in but had headlight on

How do I diagnose?

THX

John

[Bluetick1955`]

I assume the selector switch is the forward/reverse switch, I pull it. small switch p/n ZB2-BE101

Someone help please

[scottyb]

Can you identify the drive system in this cart here > https://www.cartsunlimited.net/upgrade-suggestions.html

[Bluetick1955`]

I suppose sepex. here is the switch.

[JohnnieB]

The diode on the F/R switch assembly tells me it is an early DCS drive. (See attached photo)

The DCS controller defaults to forward and is told to do reverse by applying battery voltage on Pin-4 (orange wire). (See attached schematic)

Check for voltage on Pin-4 when F/R is in Reverse. If it is, the controller is likely to be bad.

If it is, replace it with an Alltrax XCT48400DCS. The DCS controller (Curtis 1206SX) was a failed design.

Also, the F/R switch assembly can be replace with DPDT/center off (On-Off-ON) toggle switch. (See attached drawing)

[JohnnieB]

Just noticed the orange wire label on the drawing says Pin-9, should be Pin-4.

Let me verify that drawing is correct before using it.

[bluetick1955]

Thanks! you are a big help

[Bluetick1955`]

Originally Posted by JohnnieB

The diode on the F/R switch assembly tells me it is an early DCS drive. (See attached photo)

The DCS controller defaults to forward and is told to do reverse by applying battery voltage on Pin-4 (orange wire). (See attached schematic)

Check for voltage on Pin-4 when F/R is in Reverse. If it is, the controller is likely to be bad.

If it is, replace it with an Alltrax XCT48400DCS. The DCS controller (Curtis 1206SX) was a failed design.

Also, the F/R switch assembly can be replace with DPDT/center off (On-Off-ON) toggle switch. (See attached drawing)

I am a little confused. here is a pic of the back of switch. 2 #4. Also when checking does my neg lead go to a neg post on battery?

[jgreene]

johnnie B

Could it be the diode is bad? How would you check it

[JohnnieB]

Unless stated otherwise, the voltmeter's negative test lead is connected to the battery pack's main negative terminal.

The diode is good or the cart would not have moved when F/R lever was in R.

To get cart to move in either direction, 36V has to be applied to Pin-5.

In the F position, the voltage passes through the top switch on the schematic to the keyswitch, then on to the solenoid coil, where is is paralleled to Pin-5.

In the R position, the voltage is passed through the bottom switch and parallel to two places. The orange wire goes to Pin-4 and tells controller to go into the reverse mode of operation and the diode passes the voltage to the keyswitch, eventually getting to Pin-5 and telling controller to run.

AS previously stated, when the cart moves forward when direction selector is in R, either the voltage is not getting to Pin-4 for some reason, or the controller is being told to go into reverse mode and is not doing what it is being told to do, so the controller is bad.

Since it is intermittent, try unplugging the connector on top of the controller, spray cleaning and reconnecting.