A2 Wire very warm and Controller post melted – Causes?

FiveStars19

I have a 2003 Club Car DS IQ – Lifted in 2006 with D&D motor and Curtis Controller (250V).

Been trouble free for years but suddenly cart only gives about 2 slow revolutions of tires in either directions and quits.

50.8v across battery pack (3yr old Trojan batteries). I replaced Solenoid and MCOR and then found some melted plastic on controller post which connects both the Yellow (from Solenoid) and the Green (A2 of Motor). Both of these wires are warm to touch after trying to have it run on jack stands.

I did free roll test as described on this site and get no beeps and the cart has no resistance - it rolls freely.

Any suggestions on what I should do next? Do I replace the speed sensor or dig further first? What do you think would cause melting on the controller or these wires to get so warm/hot? I don’t want to put in another controller until I find out what failed first. Thoughts that it could be the motor?

Thanks in advance!

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Fairtax4me

A melted post is usually due to a poor connection. Either the terminal was loose, or the crimp on the cable end was loose or corroded inside.

That much heat on the controller terminal could cause solder connections inside to melt.

Try replacing both of those cables and see if the controller still works.
Also test the motor for shorts to make sure there is not a problem in the motor causing high amp draw through that cable connection.

FiveStars19

Thanks for the info. I took your advice and changed both wires but problem still remains. Any suggestions on how to test the D&D motor?