Gear selector getting hot

[twistr25]

Had a couple of previous posts, recently upgraded to 3 12v 100Ahr batteries, but I'm noticing now that my gear selector is getting hot and has that kind of electrical smell. I would have thought it would have gone away by now if there was any "new wire" effect, but it's still around. I am getting 40 volts to the switch. What things should I be checking for?

I assume there is a chassis ground either off the motor or controller, but should I be looking anywhere else? Trying to make sure I don't have a short too.

[LukeL]

Originally Posted by twistr25

Had a couple of previous posts, recently upgraded to 3 12v 100Ahr batteries, but I'm noticing now that my gear selector is getting hot and has that kind of electrical smell. I would have thought it would have gone away by now if there was any "new wire" effect, but it's still around. I am getting 40 volts to the switch. What things should I be checking for?

I assume there is a chassis ground either off the motor or controller, but should I be looking anywhere else? Trying to make sure I don't have a short too.

By gear selector I assume you mean rotary style forward/reverse switch? Are the cables that attach to it getting hot as well? It likely needs to be upgraded due to the other upgrades you’ve done to your cart. It’s possible that you may be able to clean or replace the contacts inside of it but at this point a reversing contactor may be your best upgrade.

And there is/should be NO chassis ground on an electric cart.

[augiedoggy]

Would 3 12v 100ah batteries be an upgrade that would somehow cause more current to reach the motor or more resistance through the wiring/switch vs 6 6v batteries?
Are these lithium? What voltage did this cart start out as?.. Was the wiring connections cleaned when this was done? just wondering if there a poor connection somewhere causing resistance.

Unless a voltage change, bigger controller or motor has also been installed there should be no reason to cause increased current to be pulled through the switch.

[twistr25]

Originally Posted by LukeL

By gear selector I assume you mean rotary style forward/reverse switch? Are the cables that attach to it getting hot as well? It likely needs to be upgraded due to the other upgrades you’ve done to your cart. It’s possible that you may be able to clean or replace the contacts inside of it but at this point a reversing contactor may be your best upgrade.

And there is/should be NO chassis ground on an electric cart.

Yes, forward/reverse switch. Did a little more investigating and it is definitely coming from the cables going to/from the motor. Cable marked with D was super hot when I did some testing today. I did not clean or swap any connectors or cables in from the selector back towards the motor. I only updated the batteries. A few pictures added again.

Previous battery set was 6 6v lead acid batteries in series. I upgraded to 3 12v lithiums. I can't tell if anything is pulling any extra current, but all voltages seem legit. Maybe it needs upgraded cables too, just doesn't seem to make sense why since the total voltage bank is technically the same, but not my expertise either.