Help! my golf cart’s F/R switch keeps melting

Desperately need advice! I’ve got a 2006 EZGO TXT converted to 48v, and I’m constantly facing a nightmare with the forward/reverse (F/R) switches melting. I’ve tried a few things, but nothing seems to stick. It’s ruining my golfing days. Has anyone tackled this issue successfully? Any help would be a lifesaver!

Response

Switching to a heavy-duty reversing contactor worked best for me. It might cost a bit, but it’s worth every penny for the peace of mind. Definitely worth considering!

Solutions that Worked for Users

Solution	Users Who Found Success	Approx. Cost (USD)	Approx. Time Needed (Minutes)
Switch to Heavy-Duty Reversing Contactor	3	$150 – $250	60 – 90
Upgrade to 4/0 Welding Cable for Connections	2	$100 – $200	45 – 75
Adjust F/R Switch Alignment	1	$0 – $20	30 – 45
Replace F/R Switch with EZ575	1	$120 – $180	50 – 70

Symptoms

• Persistent melting of the F/R switch contacts.
• Power issues or failure to switch directions correctly.
• Overheating around the F/R switch area.

Possible Causes

• Inadequate switch or cable capacity for the cart’s power requirements.
• Misalignment or connection issues in the F/R switch.
• Excessive amperage draw due to cart modifications or upgrades.

Solutions that Worked

1. Switch to Heavy-Duty Reversing Contactor
   • What I Did: Upgraded from a standard F/R switch to a heavy-duty reversing contactor.
   • Outcome: No more melting issues, and smoother operation.
   • Personal Experience: This upgrade not only solved the melting problem but also improved the overall performance.
   • Detailed Steps:
     1. Research and purchase a compatible heavy-duty reversing contactor.
     2. Safely disconnect the cart’s power source to avoid any electrical hazards.
     3. Carefully remove the existing F/R switch, noting the wire connections.
     4. Install the new contactor, ensuring all connections match the original setup.
     5. Securely fasten the contactor and double-check all connections.
     6. Reconnect the power and conduct a test run to check for proper functionality.
   • Handy Tips: Make sure the contactor is rated for your cart’s specific voltage. A contactor with higher amperage capacity can better handle increased power demands.
2. Upgrade to 4/0 Welding Cable for Connections
   • What I Did: Replaced existing cables with thicker 4/0 welding cables.
   • Outcome: Enhanced power handling and reduced overheating.
   • Personal Experience: The cable upgrade noticeably improved the electrical flow.
   • Detailed Steps:
     1. Identify all key electrical connections needing an upgrade.
     2. Remove the existing cables, taking care to remember their routing.
     3. Replace them with 4/0 welding cables, ensuring secure and clean connections.
     4. Test the cart for any signs of overheating or power issues.
   • Handy Tips: Regularly inspect and clean cable connections to maintain optimal performance. Ensure the cables are not too tightly coiled or bent, as this can cause resistance.
3. Adjust F/R Switch Alignment
   • What I Did: Realigned the F/R switch for full contact.
   • Outcome: Fixed the partial contact issue, preventing overheating.
   • Personal Experience: Proper alignment was crucial in stopping the switch from melting.
   • Detailed Steps:
     1. Locate the F/R switch, typically under the seat or dashboard.
     2. Loosen its mounting screws for adjustment.
     3. Shift the switch to ensure it clicks firmly into each position.
     4. Tighten the screws and test the switch function.
   • Handy Tips: Regular checks and adjustments of the F/R switch can prevent future issues. Listen for a distinct click as a sign of proper engagement.
4. Replace F/R Switch with EZ575
   • What I Did: Switched to a more durable EZ575 switch.
   • Outcome: The new switch handled the power demands without issues.
   • Personal Experience: This switch proved much more reliable than the standard one.
   • Detailed Steps:
     1. Acquire the EZ575 switch, ensuring compatibility with your cart.
     2. Disconnect power and carefully remove the old switch.
     3. Install the EZ575, paying attention to proper alignment and connection.
     4. Reconnect power and test the cart.
   • Handy Tips: When upgrading components like switches, consider how they interact with other modifications in your cart. A mismatch can lead to further issues.

Golf Cart Models Where This Worked

• Various models of EZGO, especially those modified or upgraded for higher performance.