Forward Reverse Switch Replacement - 1992 Club Car DS 36V

[hhraulerson]

I'm replacing the forward reverse switch on my 1992 Club Car DS (electric 36V). I'm unsure how to wire the forward reverse switch correctly after installing the new switch. The original switch only had 5 leads (see 2 original switch photos). I have 5 wires (white, white with black line, black, red with white line, green with white line) coming from the golf cart that were attached to the original switch. (see wires_from_golf_cart.webp). There was also an orange wire that was not connected to the original switch.

The new switch has 2 leads plus 5 additional wires coming off of it (plus red wire coming from switch is capped at the end). These 6 wires (if you include capped red one) are grouped into 2 sets of wires. The first is black, blue, and then red capped wire from top to bottom. Second group is green, black, and white wires (see new_switch_top.webp). I've been able to play around with the wires and get either forward or reverse to work, but no combination that allows forward and reverse to work at the same time.

If any of the experts here could help me figure out this wiring issue, I'd be incredibly appreciative. Thank you!

 

[Notsoslim]

It looks like you just need to hook up the wires to the 3 micro switches. They go back in the same order as they were attached before. The wire that were attached to the microswitch closest to the battery should go back in the same position and so on. This diagram tells you what color wire from the cart goes on what terminal.

 

[hhraulerson]

Thank you for the reply. So the orange wire does need to be connected to the middle microswitch (limit switch)?

 

[Notsoslim]

Shows orange hooked to bottom of middle MS with red/white hooked to top of middle MS

 

[hhraulerson]

Thank you. I'll give that a try and see if it works.

 

[Notsoslim]

Here is a manual for your cart. Wiring diagram on page 12-10

https://mobilicab.com/F4hxm7zhX073ecq/1992-DS-Golf-Car.pdf

 

[hhraulerson]

Thank you so much for sharing!

 

[hhraulerson]

Below is my current wiring based on the diagram. There's an extra wire on microswitch #3. Think I have this wired correctly. Reverse buzzer is coming on, but cart won't go in either forward or reverse.

Is it possible that I screwed something else up by wiring the forward reverse switch wrong initially?

 

[Notsoslim]

I can't tell what you have done from that photo. Is the cart doing the same thing it did before? You never said why you changed to FNR switch to start with.

 

[hhraulerson]

I changed it because it was randomly just popping out of gear. It worked before replacing the switch.

 

[Notsoslim]

I should have asked if your cart is a resistor cart or does it have a solid state controller? And can you describe the symptoms any better? When you say it "pops out of gear" does that mean it loses all power? If doesn't necessarily sound like the FNR switch. Have you checked the voltage on the batteries? Do you have a multimeter? It is best to diagnose the issue before randomly replacing parts.

 

[hhraulerson]

It's a solid state cart. Symptoms were that the cart suddenly wouldn't go when it was in gear at random points during a ride. When I messed with the gear shifter/switch handle, it would quickly engage and work again.

I don't have a multimeter but I'll go grab one. I'll check the voltage on all the batteries and report back. Thank you again for all the help!

 

[hhraulerson]

Battery 1: 6.79V
Battery 2: 6.8V
Battery 3: 6.7V
Battery 4: 6.79V
Battery 5: 6.73V
Battery 6: 6.83V

Battery 6 is new as of 2 months ago. Here's a diagram of how I have the microswitches wired with the wires on the left side coming from the golf cart.

 

[hhraulerson]

Solenoid is not clicking when ignition switch is turned on nor when pedal is depressed. Also, what should voltage be on microswitch wires when ignition is turned on?

 

[hhraulerson]

Any help would be greatly appreciated.

 

[Notsoslim]

. It worked before replacing the switch.

Put it back the way it was. After that some diagnostics are in order.