Resistor cart gets hot

[tyhuck]

Originally Posted by crash test dummy

if it was safe to wire the motor to the batteries the manufacture would of done it
there are times when you need to control the speed of the cart ... crowds, parades , turns , and pulling in to parking space

I can see bypassing the resistor completely and only having 1 speed, but when you have 5 speeds and the last one is WOT anyway, whats the harm in bypassing the resistor at that point? At that point on the wiper board, the current doesn't even pass through a resistor coil the way the factory wires it.

[tculpepper]

Exactly. You aren't always running wide open, only when the pedal is pushed all the way. Just like with original wiring, only not weak points in between.

i see ... ok ... your over kill is good but not needed ... it's a matter of one nut and bolt

Newbie22 if i remember right the ezgo does not have a heat shield
, i know on my club car there is an aluminum heat shield , you might look into getting one for the cart

[tyhuck]

Not sure what year you are running, but here is the one I ran on my 86.

http://www.ebay.com/itm/EZGO-Maratho...-/380469293633

Worked great. It did get hot, but never hot enough to catch on fire. Like I said before, I ran it to the point of melting the F/R switch, and it didn't phase the resistor at all. Since I primarily used mine offroad at the deer leased, I did add a thin gauge steel shield underneath it though to prevent tall grass and stuff from contacting the coils when parked. Last thing I wanted was to catch the woods on fire.

[tculpepper]

That's what my I'm guessing stock resistor shield looks like. like you said, it does get HOT! I like the idea of putting a shield on the bottom. I'll have to add that to my to do list. Catching everything on fire and burning down the woods is not my idea of fun.

[Newbie22]

Tyhuck, that not quite what mine looks like, mine is the red fibre board style, but maybe if I put one in like that one it would eliminate the fibre catching on fire......

Originally Posted by Newbie22

Tyhuck, that not quite what mine looks like, mine is the red fibre board style, but maybe if I put one in like that one it would eliminate the fibre catching on fire......

we never asked or i missed it

[tyhuck]

Originally Posted by Newbie22

Tyhuck, that not quite what mine looks like, mine is the red fibre board style, but maybe if I put one in like that one it would eliminate the fibre catching on fire......

Yeah, what you described is exactly what my 86 model Marathon had when I got it, but the resistors were corroded (some in half) and the fiber board was crumbling, so I replaced it with the upgrade. I didn't even run the factory resistor, obviously because it wasn't a complete circuit, but also because I was afraid of a fire.

[phnguyk]

The motor is probably on it's way out, it's probably running inefficiently (windings worn, brushes worn, bearings worn) drawing a high amount of amps. Higher amps cause the resistor coils all the way to the batteries to run extremely hot. I'd either convert, buy different gc, or try having motor rebuilt/rewound.

[phnguyk]

btw the resisitor coils are probably worn which will cause excessive heat, just replacing them may work for a bit but will be overheated sooner than later.