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Unread 01-10-2009, 09:22 AM   #1
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Default Burned Cable

I volunteered to help a hunter's club with an old EZ-GO electric cart. The model number is G1388. It has a burned cable coming off the resistor on the second post from the front of the cart. It smelled hot when he took me for a ride and that's when I volunteered to look at it. Now that I have it at my home and started inspecting it I see the burned wire. It's not completely burned in two but close.

I have zero experience working on an electric cart. I did, however, work as the operations manager for a golf course for 10 years and got to know Yamaha and Club Car gas models pretty well. Needless to say this is a whole new can of worms for me. After looking at all the heavy gauge wires I can just imagine myself not hooking one of them back to it's proper post and creating havoc. I'll replace one wire at a time to avoid embarassment!!!

I might also mention that this cart is one of those camo, 4-seaters with the big tires.

So here's my questions if anyone is patient enough to deal with me:

1. Most of the heavy gauge wires look like a hodge podge of repairs over the years. I'd like to clean it all up and run new wires. I think the current gauge is 6. Can I use 4 gauge without any problems?

2. I plan to buy a length of welders cable and put the lugs on each end myself. I would like to solder them on instead of crimping them and then follow with shrink wrap so they look professional. Any problem here?

3. The controller thingy that esentially makes it look like a four speed electric motor is somewhat charred. I assume it still works okay but the replacement cost is negligible for the contacts and the striker so I thought I would replace it while I have it here. Good Idea? Bad Idea?

4. The gang of resistors looks feeble and I think I should replace that as well?

Anything else come to mind that this model is notorius for needing or should I be checking anything in addition?

This site looks like a wealth of information and I appreciate any effort you give to help me with this sproject.


Jeff
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Unread 01-10-2009, 09:55 AM   #2
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Default Re: Burned Cable

Quote:
Originally Posted by Dinkie Diesel View Post
I volunteered to help a hunter's club with an old EZ-GO electric cart... I have zero experience working on an electric cart... Most of the heavy gauge wires look like a hodge podge of repairs over the years... The gang of resistors looks feeble...
Jeff
Can you UNvolunteer yourself? You have a 21 year old cart with 21 year old electronics. Resistor coil carts are NOT made to run at half speed, that's why you get hot cables. Add to the fact that it is a 4 seater, larger wheels and runs off road, that only adds more stress to a stressed system.

In our experience with these carts at our shop, I would suggest replacing ALL cables with 4 gauge and replace the resistor board / coil assembly. You didn't say, but I'll assume that this cart has a wiper board / moveable contact assembly (throttle portion)? That will need to be addressed / replaced if it shows signs of wear. Batteries may be at the end of their lifetime, especially the ones with burned lugs? Did you get a repair budget before you started?

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Unread 01-10-2009, 10:13 AM   #3
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Default Re: Burned Cable

Thanks MMT! What a quick response. I had to laugh at your answer of UN-volunteer as I knew exactly what was to follow. I think all parties will be happy if I can patch it up for $250 or so and let the hunters use it again. It probably gets about 6-10 hours of use a year and they aren't willing to spend for a replacement just yet.

Yes, it does have the moveable contacts. That's my reference in the "controller thingy" to the moveable contacts. I suppose I'll replace them too. The batteries (all 6) are new as of April 08.

Thanks again!
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Unread 01-10-2009, 12:05 PM   #4
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Default Re: Burned Cable

Wow, $250.00?
Take that and buy the hunters new walking boots!
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Unread 01-10-2009, 12:58 PM   #5
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Default Re: Burned Cable

Doubt if you'll get it done correctly for $250.00, but good luck! I'd guess you'll get in over $500.00...

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Unread 01-10-2009, 07:00 PM   #6
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Default Re: Burned Cable

MMT is right. To get cart running correctly you will spend some bucks. But what are you looking for. I ran my old resistor cart with only two speeds for a year(stop,wot). Be sure to keep those resistor coils out of the creeks. Water on red hot metal leads to broken resistors.
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Unread 01-10-2009, 07:53 PM   #7
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Default Re: Burned Cable

Sure, go ahead guys, try to depress me even more! I can assure you this cart has never seen WOT during their ownership. They drone along at 4 or 6 MPH no matter where they go. There are no hills on their duck hunting property, luckily. The resistors are mounted high, just under the seat and they don't use it like an ATV.

I'm going install 5 new contacts on the board, new moveable wiper contact, new resistor gang, all new secondary leads and see what I get. I also see what looks like a light duty solenoid on this thing. The kind you'd see on Murray lawn mower. I'm sure its ampere rating is less than optimum.

Thanks again for your help!
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Unread 01-10-2009, 08:35 PM   #8
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Default Re: Burned Cable

Quote:
Originally Posted by Dinkie Diesel View Post
Sure, go ahead guys, try to depress me even more! I can assure you this cart has never seen WOT during their ownership. They drone along at 4 or 6 MPH no matter where they go. There are no hills on their duck hunting property, luckily. The resistors are mounted high, just under the seat and they don't use it like an ATV.

I'm going install 5 new contacts on the board, new moveable wiper contact, new resistor gang, all new secondary leads and see what I get. I also see what looks like a light duty solenoid on this thing. The kind you'd see on Murray lawn mower. I'm sure its ampere rating is less than optimum.

Thanks again for your help!
That's a large part of the problem.. Resistor carts don't like plodding along at very low speeds.. The resistors build up an enormous amount of heat, cooking everything near them.. The resistor carts run cooler and more efficiently at WOT..
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Unread 01-10-2009, 09:09 PM   #9
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Default Re: Burned Cable

Does IPC still make the Hi-Perf resistor coils?
I'll help your budget along a bit. I have some parts on the shelf for that cart. PM me for details.
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Unread 01-10-2009, 09:19 PM   #10
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Default Re: Burned Cable

I got another one for ya.

This resistor gang has an aluminum box around it. I see two different Res. Gangs on the parts lists. Somethings tells me it has the wrong resistor gang on it. The aluminum box has 4 holes with which to mount the res. board.

I've attached a picture if it's clear enough to see.
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File Type: jpg CRW_2832 (Medium).JPG (69.8 KB, 44 views)
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