keep hunting cart from burning up controllers

[robnhood]

My friends hunting cart is having problems. he has a 36 volt series ezgo lifted with 22's/rear seat and stock components. it has already burnt up one controller and he had it replaced at the shop with the factory controller. well he called me yesterday and it would not go so he brought it by to see if i could figure it out. the wire going from the foward reverse switch to the controller had melted against the solenoid and burnt a post on the solenoid i pput new wires on it to see if it would work but still no go. the solenoid is clicking but nothing happens. i will check the voltage through everything this afternoon. i wasn't around when it burnt so i don't know what really happened but from the looks of the wire it is way too hot in the controller box. would that for sure fry the controller? and what all would he need to do to keep the heat down after we fix the problem to protect it in the future?
sorry for the long post. thanks

[caokgafamily]

Robinhood,
A friend of mine was having the same problem. He upgraded his controller to an 500 amp Alltrax and he hasn't had any more probs.
Steve

[scottyb]

You need to go deeper into upgrading the drive system than just the control. The controller is like a gate valve for the battery amperage. If you increase the size of this valve for more amperage delivery then you also have to upgrade the delivery system for this increased amperage ... or you will create a bottleneck (resistance) and the resulting heat will melt wires, solenoids, & F&Rs

robnhood's friend's cart needs a controller, solenoid, cables, and F&R upgrade to be a reliable hunting buggie.

[robnhood]

thanks guys and thanks scotty for spelling it out simple! i will show him the post so he can make the decision. i hate for him to keep replacing parts hoping it doesn't break and wasting money.

[DaveTM]

Yeah.....what Scotty is saying is true. My hunting cart has been running year round for 5 years and it really does get pounded. (well.....stuff that breaks is usually my fault....don't go back to my controller post....that was all my fault!!!)

But with the right wiring, F\R switch, and controller....you'll be out dare!!!

Dave

[scottyb]

I hate to see guys put a replacement stock or rebuilt stock controller on their hunting cart. I know it won't last but a little while and after buying 2 or 3 of em you could have had a big upgrade.