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Old 11-19-2011, 12:01 AM   #1
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Question 36v ezgo model 960 with overheating resistor coils

I have a 36volt 4 seat Ezgo that says model# 960 Serial# 44370586. The problem is I cannot find any info on this cart, like it dosen't exist. I assumed that by the serial it might be a 1986. Someone said it was an industrial model but I can find no information. Beyond trying to identify what I really have, there is also a problem with the two resistor coils getting so hot they glow, one even partialy melted in about 3-5 minutes of use. There are 7 solenoids and the two resistor coils are attached to the first two solenoids from the left. I have a wiring diagram that seems to be what I have but I can find no info on the manual # DPC-86 that is printed at the top of the page. Any help would be greatly appreciated.
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Old 11-19-2011, 09:27 AM   #2
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Default Re: 36v ezgo model 960 with overheating resistor coils

Maybe you could post some pics of the cart and the working guts of it? IT sounds like one of the original industrial models ...
What is your intended use for the old beast?
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Old 11-19-2011, 10:33 AM   #3
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Default Re: 36v ezgo model 960 with overheating resistor coils

Welcome to BGW.

If your cart matches the schematic you posted, it's a fairly simple, straightforward design.
The schematic is laid out poorly, so it is confusing, but the design itself is about as basic as it gets.
All the control circuits are low amperage and all the High Current switching is done with solenoids.

You've got three speeds.
In "Low" total battery current flows through two resistor coils and the motor.
In "Medium" total battery current flows through one resistor coil and the motor.
In "High" total battery current flows through the motor only.

Forward and Reverse is done by changing the relative direction of current flow through the motor's armature and stator windings via two set of solenoids that are controlled in parallel pairs.

It is inefficient since you draw almost same amount of current from the battery no matter which of the three speeds you are running in. (The "High" speed is the most efficient.)

The resistor coils getting hot is normal when the two lower speeds are used.
As the coils are used over time, they slough off the outermost layers, then get hotter when used and will eventually melt.

Replacement coils might be available, or perhaps coils for a different model resistor cart might work.

Or, it might be possible to convert the resistor coil type drive with an electronic speed control type.
However that would be a major undertaking that will require considerable electrical and mechanical knowledge and skills.

You also might identify the model/year by calling E-Z-GO Customer Support at 1-877-394-6727
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