Cart has several issues, need advice

[cyclebender]

Recently purchase a 2000 TXT 36 volt series cart, Rebuilt the motor, and installed new batteries. Replaced all cables with 4 ga, and applied dielectric grease. Cart ran good, but only for 20 min. Cart just lost power. Pressed the accelerator several times, could hear the solenoid engage (click) After shifting to reverse the cart started to move, shifted back to forward and the cart started to move again. After about 10 seconds the same thing happened, I repeated this procedure several times to get the cart back to the shop, Removed the cam plate from the f/r switch, cleaned all contacts, applied dielectric grease on brass lugs, assembled in back and tighten the center nut as tight as I could, Tried the cart again, worked for about 10 minuets and quite again. Towed in back. Checked all electrical connections. Getting good continuity between the brass lugs on the f/r switch, but I know that's no guarantee that the lugs will pass full voltage. When I checked the solenoid, I found that I had full voltage on both terminals. Apparently the resistor was blown and allowing full voltage to pass between the two terminals (pedal not depressed) My meter showed full continuity at each end. Any idea what caused this, and do you think the two problems are related? I don't intend to run the cart without the resistor, as I read on this forum that it could cause arcing and considerable damage to the electrical system, I have ordered a new resistor online, will try again when it arrives. I also read the the f/r switch is prone to failure after 10 years. Instead of purchasing the complete switch, could I just purchase a new HD cam plate with lugs from Carts Unlimited? The guys on this board are great, lots of knowledge all willing to share, thanks for any insight you can offer.

[scottyb]

For testing you can run without the resistor - its easier to trouble shoot without it. Sounds like your F&R may be the problem, disconnect the linkage and remove the center pivot shaft nut (rear side) slide the shaft and switch cam out (*forward) for inspection. Any sign of heat (dis color) or arcing and you will need a new heavy duty switch.

[cyclebender]

Thanks for the advice Scotty. Tried the cart without the resistor, ran fine. Just don't understand why the resistor went bad.

[kgsc]

The solenoid could be failing and when that happens it will try to pull heavy current through the resistor. That will definitely kill it.