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Unread 07-13-2014, 09:06 PM   #1
Not Yet Wild
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Default Resistor Board Wiring Issues

I have a 94 Club Cart DS that I recently purchased. I knew the batteries need replaced when I bought it so I replaced the batteries and connector cables last Thursday. I also disconnected all of the accessories since they were wired directly into a batter w/o a voltage reducer.

I have since noticed a burning smell coming from the golf cart. It appears that something isn't right and two wires that connect the speed switch to the resistor board are fire hot. They are so hot that they are glowing. Can somebody explain to me why this is happening? I am not fairly knowledgeable on wiring a golf cart but I thought I knew enough to replace the batteries

Picture of the where the wires from the speed switch connects to the Resistor Board

From Under the Cart



Looking down next to the batteries



Basically the same shot without the flash (moved a little bit left). You can see the glow where the speed switch cable connects to the resistor board.

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Unread 07-13-2014, 09:32 PM   #2
Gone Wild
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Default Re: Resistor Board Wiring Issues

I think the first thing I would do, is to replace those old rusted / corroded bolts and nuts.

Then I would make triple sure the wires are good ( no hard corrosion under the insulation ) and that they go to the correct locations.

Do you have a wiring diagram?

Does the cart run ?
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Unread 07-14-2014, 05:39 AM   #3
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Default Re: Resistor Board Wiring Issues

Quote:
Originally Posted by smokey tennis shoe View Post
I think the first thing I would do, is to replace those old rusted / corroded bolts and nuts.

Then I would make triple sure the wires are good ( no hard corrosion under the insulation ) and that they go to the correct locations.

Do you have a wiring diagram?

Does the cart run ?
Yes, the cart runs fine. I am going to try to replace the wires, nuts, and bolts that connect the speed switch to the resistor board.

Unfortunately I don't have a wiring diagram. However, I drew a sketch of the wires and batteries before I replaced them to make sure everything was correctly re installed. I think everything is hooked up correctly except for the accessories, which are not hooked up. I used this diagram below that I found online to verify that everything else is correct. Everything seems like it is hooked up correctly compared to the diagram, minus the reverse buzzer.

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Unread 07-14-2014, 06:29 AM   #4
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Default Re: Resistor Board Wiring Issues

I just found this link after doing some more research. It seems like my problem is in my solenoid. Can somebody confirm that this sounds like the case?

http://www.ddmotorsystems.com/SolenoidsPage.php

"The last type of solenoid failure results when the internal plate and studs freeze to each other. In other words, the solenoid works ok, but doesn't stop working when the pedal is released. This results in the car creeping on its own when the shifter is in F or R. Sticky solenoids are more common in the older resistor style cars, but this condition, if not recognized and repaired, can be a fire hazard and at a minimum, cause the battery pack to drain. Lots of folks have seen the result of a sticky solenoid. The resistor coils glow red hot, hence the fire hazard, and why this glowing condition drains the batteries. If this situation happens to you, just shift into neutral each time you stop. Get it fixed right away! Remember that arcing we mentioned earlier? Now that arcing is occurring at the F&R switch, not the solenoid. The F&R is not designed to handle this condition."
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Unread 07-14-2014, 09:33 AM   #5
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Default Re: Resistor Board Wiring Issues

It doesn't look like you have the right resistor board assembly for that CC. The resistor boards are supposed to be one whole board, not two seperate ones. It looks like someone tried to do a quick fix. Judging by the amount of mismatched bolt and screw heads
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Unread 07-14-2014, 12:00 PM   #6
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Default Re: Resistor Board Wiring Issues

Oh no. That does not sound good. I will have to look into getting a new resistor board. Would that be the cause of my issues?
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Unread 07-14-2014, 12:53 PM   #7
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Default Re: Resistor Board Wiring Issues

It is most likely a combination of the board, mismatched bolts, corroded wire terminals, and possibly a stuck solenoid.
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Unread 07-14-2014, 01:11 PM   #8
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Default Re: Resistor Board Wiring Issues

CroZure, sent you a PM
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Unread 07-14-2014, 08:44 PM   #9
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Default Re: Resistor Board Wiring Issues

Thanks again CCFanatic for your help. I am going to look into replacing the resistor board next.
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Unread 07-20-2014, 09:26 AM   #10
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Default Re: Resistor Board Wiring Issues

Here is an Update.

I decided to drop the golf cart at a local golf cart shop to have it looked at. From what they told me, the resistor board and speed resistors were burning up because the v glide is bad. They also said that the solenoid needs replacing.
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