97 DCS cart F/R switch smoking

[dlbushey]

*Disclaimer* I have NO knowledge of Golf Carts! (Other than operation)

Hey everybody! After finding this forum 3+ hours ago and searching for some kind of information on my cart, I have discovered that I have a 1997 TXT DCS electric golf cart. (SN 1006736, Manufacture number C1697) I probably could have found out more, but I kept finding cool things to read that kept taking me off track. My ADD kicking in, I guess!

I have owned this cart for 2 years and have never had a problem, however today when I took it out for it's spring maiden voyage, while going up a hill, I began to smell the unmistakable scent of burned conductor insulation. I stopped and lifted the seat and discovered smoke coming from under the cover of the F/R switch.

I checked all of the connections on the battery as well as the F/R switch and found no loose or broken connectors. I could not find what part was smoking as nothing looked burned or felt hot. I continued back to the clubhouse without further incident.

Any ideas on what else I should check/repair/replace?

[scottyb]

The DCS F&R is mounted behind the drivers knee.... it's a round hockey puck looking thing when viewed from under the seat. No big cables connect to it just the 2 microswitches..... are you certain you have a DCS cart?

And welcome to BGW !!!

[dlbushey]

Originally Posted by scottyb

..... are you certain you have a DCS cart?

And welcome to BGW !!!

Thanks for the welcome....and no, I am not at all certain I have a DCS cart. I was going by what was said in this thread when I said I had a DCS cart.

My cart has a lever under the drivers knee that attaches via a connecting rod to a large electric component that has large cables attached to it as well as smaller wires...one of which is not attached to it's connector. When I do attach it, the reverse tone sounds when shifted into reverse.

I see no run/tow switch anywhere. The cart is about an hour away from me right now or I would take a picture and post it for you to see...but from what I can tell, it looks a whole lot like the diagram of a non-DCS vehicle seen in the Basic Ezgo electric golf cart wiring and manuals sticky.

Maybe it's not a DCS cart...I'm so confused!!!!

[scottyb]

Take a deep breath .......
What you are describbing is a series cart....... That makes more sense the F&R lever has a linkage to the actual F&R under the passenger seat. These F&Rs will burn up .... especially if one of the big cables going to it get a little loose? You can replace it with a HD switch ...

[dlbushey]

Originally Posted by scottyb

Take a deep breath .......
What you are describbing is a series cart....... You can replace it with a HD switch ...

Breathe in....breathe out....whew....all better now.

I'm surfing the EZ go website right now and don't see anything that looks like what I have in there now. What is a HD switch and where can I find one???

[scottyb]

ezgo does not make them.... I use them in my upgrades and sell them also. It is a complete bolt in unit. The onlything you reuse is the cover and the linkage rod. Lemme see if I can find you a pic?

[buddy48]

Here let me help. This is a Nivel 5799 Heavy Duty F&R switch. I believe any of the vendors here will have this one or something similar to help you out...

[scottyb]

Thanks buddy, That's the one I sent to him today

[COURTESYCART]

Also check you cable ends, if they are burn't replace the cable with 4ga. Since you are replacing that unit, i would go ahead and upgrade to complete 4ga cables.

[scottyb]

Agreed...... and just for continuity sake ....
This cart turns out to be a Series cart not DCS as the title says.