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Unread 01-19-2014, 05:17 PM   #1
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Default Cart died under heavy load

Was pulling a heavy trailer slowly to get through a gate when my cart just died. Batteries at 80%. Cart also died a couple days ago going full speed cruising. Played around with F/R switch for a few minutes and it ran again. Ran fine for a few days until now.
Now it won't move. Green light on controller goes on when pedal is depressed.
Think F/R switch finally gave up?
All wires to motor are fine. No loose wires or bad solder jobs.
It almost makes a split second movement like it wants to go.
Guessing replace F/R switch first then go from there?
Ideas anyone?
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Unread 01-19-2014, 06:34 PM   #2
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Default Re: Cart died under heavy load

Wiggle the F/R switch a bit, perhaps with the pedal down a little bit. If you can get it to run at all, stop after a short bit and carefully feel all the connections on the F/R switch. If the switch is bad, the connections will feel hot.
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Unread 01-19-2014, 07:52 PM   #3
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Default Re: Cart died under heavy load

Quote:
Originally Posted by jdunmyer View Post
Wiggle the F/R switch a bit, perhaps with the pedal down a little bit. If you can get it to run at all, stop after a short bit and carefully feel all the connections on the F/R switch. If the switch is bad, the connections will feel hot.
Thanks for the tip. Just tried it. Nothing got hot or warm...
I'll keep searching here but if anyone has more ideas, chime in...

Last edited by Extractor; 01-19-2014 at 07:59 PM.. Reason: Tt
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Unread 01-19-2014, 09:09 PM   #4
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Default Re: Cart died under heavy load

I've had this scenario happen to me and it's been a melted battery terminal. I know you said that all the wires were fine, but check all the battery connections well, under a heavy load the weakest link will be what burns up. Other than that, I'd say you probably fried the F/R switch and it isn't working as well as it should.
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Unread 01-20-2014, 12:43 AM   #5
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Default Re: Cart died under heavy load

Def start with the f/r

Sounds like a good time to upgrade to a hd contactor from scottyb.
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Unread 01-20-2014, 08:13 AM   #6
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Default Re: Cart died under heavy load

Is the solenoid clicking when you press the pedal down? If not, check the little microswitch on the F/R switch. It is there to verify that the F/R selector is fully in Forward or Reverse before applying power, and they're known to go bad.
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Unread 01-20-2014, 08:43 AM   #7
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Default Re: Cart died under heavy load

most likely you melted the post into the rotating block on the f/r switch. done this a few times before I learned to stop being cheap and buy a real switch .
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Unread 01-20-2014, 09:35 AM   #8
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Default Re: Cart died under heavy load

Quote:
Originally Posted by sunoco View Post
Def start with the f/r

Sounds like a good time to upgrade to a hd contactor from scottyb.
Quote:
Originally Posted by Swan View Post
most likely you melted the post into the rotating block on the f/r switch. done this a few times before I learned to stop being cheap and buy a real switch .
Solenoid does not click.
So, there is something beefier than my HD F/R assembly? I checked Scottyb's website and they make a super duty contactor for EZgo but I didn't see one for Club Car. Mine that I have looks like the regular HD F/R that he sells.
Is there an actual heavy duty contactor for CC? ...or all HD F/R assemblies are not created equal and Scottyb's is of better quality?
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Unread 01-20-2014, 10:09 AM   #9
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Default Re: Cart died under heavy load

The reversing contactors work with any series golf cart. The same model works in Ezgo or a Westinghouse. We have put them in Club Car and Yamaha with great results. Also if your solenoid is not clicking it sounds like the trouble you are having now is in the solenoid activation circuit. The solenoid small terminals must have 36v (or 48V) between them for it to operate. If it don't click there is no + power to the controller. so start with the F&R ms and then the wires and get the solenoid to click.

Slow trailer pulling creates the highest amp draw possible - this is a situation where stuff could melt.
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Unread 01-20-2014, 11:04 AM   #10
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Default Re: Cart died under heavy load

Excellent... ordering the super duty contactor...
Thanks!

Last edited by Extractor; 01-20-2014 at 11:05 AM.. Reason: tt
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