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Electric Club Car Electric DS, and Precedent golf cars |
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06-25-2019, 12:03 PM | #1 |
Not Yet Wild
Join Date: Jul 2016
Posts: 67
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Inherited a Club Car - battery cables getting hot (has upgraded motor)
I recently inherited a lifted Club Car with an upgraded 'Plum Quick' motor. It is a 36V (6x6V batteries), I assume a Late 80's/Early 90's model DS.
I am not very familiar with electric carts, but I have a working understanding of DC systems. The cart seems to run pretty well, with the exception of two things: 1) The battery cables get warm enough to smell like burning/melting plastic. That's a big deal on an electric cart. I assume it is caused by either the bigger motor pulling too much power, or resistance/bad cables. Maybe a bit of both. The cable terminals all look pretty clean, and everything is tight. Many of the cables appear new(er). They are 6ga, from what I can tell. I'm thinking 2ga may be a better option. 2) The cart seems to be either off, or wide open - there is no in between, ESPECIALLY IN REVERSE! It is almost impossible to maneuver in a parking lot or driveway due to the fact that it jumps so hard when you touch the pedal. I'm not sure if this is just a side-effect of the upgraded motor, or if there is an issue with limit switches, etc. My first plan of action is to upgrade the battery cables - any advice on sizes? Is there a write-up on this already that I couldn't seem to find? (Yes, I searched, but didn't see anything specific other than people having hot cables as well). Any advice is appreciated. Take care, Shawn |
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06-25-2019, 02:06 PM | #2 |
Happy Carting
Join Date: Dec 2007
Location: Southern California
Posts: 73,418
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Re: Inherited a Club Car - battery cables getting hot (has upgraded motor)
It sounds like a resistor coil drive system with a couple of solenoids not working. Can you post a pic of the gear behind the batteries?
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06-25-2019, 09:38 PM | #3 |
Gone Wild
Join Date: Jul 2016
Location: Charlotte NC
Posts: 1,165
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Re: Inherited a Club Car - battery cables getting hot (has upgraded motor)
ShawnQ,
In answer to your question, just go right to 2 Gauge cables. They will be the last set you need to buy, even if you go with hi amp controllers etc. Aflyer |
06-25-2019, 10:19 PM | #4 |
Not Yet Wild
Join Date: Jul 2016
Posts: 67
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Re: Inherited a Club Car - battery cables getting hot (has upgraded motor)
I dug around a little more, and started looking at the cables a little more. I did find some cables that are in need of repair, but not the battery cables. They look pretty good aside from where they got hot. I don't think the heat was from poor connections.
Here's a shot of the resistor coil area (it is obviously one with resistor coils). In reading, I found solid-state conversions. However, this one appears to already have a new F/R switch, and has an obvious aftermarket box on it. You can see it in the last pic (red/silver box mounted under the back side of charger port) I'm still trying to figure out what each component is...so bear with me. |
06-25-2019, 10:20 PM | #5 |
Not Yet Wild
Join Date: Jul 2016
Posts: 67
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Re: Inherited a Club Car - battery cables getting hot (has upgraded motor)
BTW, found out it is in fact an 81 model, based on the first few digits of the serial number, A81
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06-25-2019, 11:19 PM | #6 |
Gone Insane
Join Date: Oct 2016
Location: Richmond, VA
Posts: 14,215
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Re: Inherited a Club Car - battery cables getting hot (has upgraded motor)
I would do as Aflyer suggested and upgrade the battery cables now.
Per Scotty's post, do you hear each solenoid click in as the pedal goes down? Could you explain "solid state conversions and aftermarket box?" |
06-25-2019, 11:59 PM | #7 |
Gone Insane
Join Date: Oct 2016
Location: Richmond, VA
Posts: 14,215
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Re: Inherited a Club Car - battery cables getting hot (has upgraded motor)
After a closer look, I think you have some issues with the FNR (forward neutral reverse switch).
Unhook the pack main cables and jack up the rear of this cart until it is sorted out. Please post a straight on photo of the whole FNR so we can see what you have. |
06-26-2019, 12:42 AM | #8 | |
Not Yet Wild
Join Date: Jul 2016
Posts: 67
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Re: Inherited a Club Car - battery cables getting hot (has upgraded motor)
Quote:
It looks like it has the resistor coils still attached, but using a much smaller gauge wire than the factory v-glide photos I have found online. The FNR switch is definitely newer. I will jack it up and crawl under it tomorrow, and try to figure out exactly how it's wired. I'm still not sure what the silver/red box is under the charger port. I figured that was a controller of some sort. For the record, here's the serial number Sent from my SM-G965U using Tapatalk |
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06-26-2019, 01:08 AM | #9 |
Gone Insane
Join Date: Oct 2016
Location: Richmond, VA
Posts: 14,215
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Re: Inherited a Club Car - battery cables getting hot (has upgraded motor)
You don't have a V-glide.
The original FNR is obsolete but others will work. That box is not a controller. Please post a photo of the entire FNR. |
06-26-2019, 01:22 AM | #10 |
Gone Insane
Join Date: Oct 2016
Location: Richmond, VA
Posts: 14,215
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Re: Inherited a Club Car - battery cables getting hot (has upgraded motor)
BTW, from what you describe in your first post, this cart is an excellent candidate for a RUNAWAY cart. It could kill you and others. Jack it up until it is sorted out.
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