New speed controller gets hot.

bguill · 05-24-2010, 11:06 PM

I just replaced my batteries and my speed controller burnt up. I replaced the controller today and ran my cart for about 3 min. When I parked it you could smell electrical. I plugged my cart in and the charger just clicks on and goes right back off. This happens ever 3 sec. Do I need to replace something else? What could be wrong?

scottyb · 05-24-2010, 11:39 PM

Welcome to BGW!
We are gonna need a list of info to wrap our minds around this one ....
Specific info on cart, batteries, controllers, and any modifications.

bguill · 05-24-2010, 11:57 PM

It is a 1998 ez-go. The batteries are trojan and I think they are a t-150. The motor was replaced with an original motor. The speed controller is a rebulit ez-go. The where about 7 years old before I replaced them. I was told that is what caused my controller problem. I replaced the batteries Saturday and ran the cart for about 15 min and somke was coming from the controller. I took it off and it had something rattling in it. I replaced the controller today and ran it for a few min and I could smell something burning. I parked the cart because I did not want to burn the controller uo.

scottyb · 05-25-2010, 12:09 AM

Is this a DCS cart? Does the cart have big tires and a rear seat? (Trojan T105

) What is the battery pack voltage? Who is rebuilding your controllers? OR are they new?

bguill · 05-25-2010, 12:20 AM

Not sure what a DCS is.. Sorry not that up to date on that. The cart has stock wheels and tires. There is no rear seat. I think it was a reman from curtis. I purchased it from a local ez-go dealer. I gave them the controller that was on it so they could match it up. I think it is a 36 volt. It had 3 logs on it and a five pen slide on white plastic. The controller hooked up the same way the old one did.

scottyb · 05-25-2010, 12:26 AM

First we have to ID your cart :

DCS will have a F&R lever behind the driver's knee and a run/tow switch on the enviromental cover on the controller. The backside of the f&R looks round like a hockey puck.

PDS carts will have a Tow/Run switch with toggle switch for F&R on the dash

SERIES carts will have a shift lever like the dcs cart down by your legs, but it will NOT have a tow/run switch. Also the actual F&R switch is in the corner by the controller and there is linkage from it to the lever in the center.....

WHich one is it?

bguill · 05-25-2010, 12:28 AM

It is a DCS.

bguill · 05-25-2010, 12:31 AM

Sorry, it is a series. It only has the f&d down by your legs. There is no other switch on it.

bguill · 05-25-2010, 09:28 PM

I think I might have figured out my problem. I ran my cart for about 2 min and started feeling for hot wires. Then I touched one of the lugs and burnt the tip of my finger. The wire was full of cracks on the underside of it. I will let you know if it fixes my problem.

bguill · 05-27-2010, 03:36 PM

FYI: I have a issue with a bad cable. There was a crack in the ubderside of the wire, which was not visible looking down on it.

05-24-2010, 11:06 PM	#1
bguill Not Yet Wild Join Date: May 2010 Location: Kenyucky Posts: 7	New speed controller gets hot. I just replaced my batteries and my speed controller burnt up. I replaced the controller today and ran my cart for about 3 min. When I parked it you could smell electrical. I plugged my cart in and the charger just clicks on and goes right back off. This happens ever 3 sec. Do I need to replace something else? What could be wrong?

05-24-2010, 11:39 PM	#2
scottyb Happy Carting Join Date: Dec 2007 Location: Southern California Posts: 73,410	Re: New speed controller gets hot. Welcome to BGW! We are gonna need a list of info to wrap our minds around this one .... Specific info on cart, batteries, controllers, and any modifications.

05-24-2010, 11:57 PM	#3
bguill Not Yet Wild Join Date: May 2010 Location: Kenyucky Posts: 7	Re: New speed controller gets hot. It is a 1998 ez-go. The batteries are trojan and I think they are a t-150. The motor was replaced with an original motor. The speed controller is a rebulit ez-go. The where about 7 years old before I replaced them. I was told that is what caused my controller problem. I replaced the batteries Saturday and ran the cart for about 15 min and somke was coming from the controller. I took it off and it had something rattling in it. I replaced the controller today and ran it for a few min and I could smell something burning. I parked the cart because I did not want to burn the controller uo.

05-25-2010, 12:09 AM	#4
scottyb Happy Carting Join Date: Dec 2007 Location: Southern California Posts: 73,410	Re: New speed controller gets hot. Is this a DCS cart? Does the cart have big tires and a rear seat? (Trojan T105 ) What is the battery pack voltage? Who is rebuilding your controllers? OR are they new?

05-25-2010, 12:20 AM	#5
bguill Not Yet Wild Join Date: May 2010 Location: Kenyucky Posts: 7	Re: New speed controller gets hot. Not sure what a DCS is.. Sorry not that up to date on that. The cart has stock wheels and tires. There is no rear seat. I think it was a reman from curtis. I purchased it from a local ez-go dealer. I gave them the controller that was on it so they could match it up. I think it is a 36 volt. It had 3 logs on it and a five pen slide on white plastic. The controller hooked up the same way the old one did.

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05-25-2010, 12:26 AM	#6
scottyb Happy Carting Join Date: Dec 2007 Location: Southern California Posts: 73,410	Re: New speed controller gets hot. First we have to ID your cart : DCS will have a F&R lever behind the driver's knee and a run/tow switch on the enviromental cover on the controller. The backside of the f&R looks round like a hockey puck. PDS carts will have a Tow/Run switch with toggle switch for F&R on the dash SERIES carts will have a shift lever like the dcs cart down by your legs, but it will NOT have a tow/run switch. Also the actual F&R switch is in the corner by the controller and there is linkage from it to the lever in the center..... WHich one is it?

05-25-2010, 12:28 AM	#7
bguill Not Yet Wild Join Date: May 2010 Location: Kenyucky Posts: 7	Re: New speed controller gets hot. It is a DCS.

05-25-2010, 12:31 AM	#8
bguill Not Yet Wild Join Date: May 2010 Location: Kenyucky Posts: 7	Re: New speed controller gets hot. Sorry, it is a series. It only has the f&d down by your legs. There is no other switch on it.

05-25-2010, 09:28 PM	#9
bguill Not Yet Wild Join Date: May 2010 Location: Kenyucky Posts: 7	Re: New speed controller gets hot. I think I might have figured out my problem. I ran my cart for about 2 min and started feeling for hot wires. Then I touched one of the lugs and burnt the tip of my finger. The wire was full of cracks on the underside of it. I will let you know if it fixes my problem.

05-27-2010, 03:36 PM	#10
bguill Not Yet Wild Join Date: May 2010 Location: Kenyucky Posts: 7	Re: New speed controller gets hot. FYI: I have a issue with a bad cable. There was a crack in the ubderside of the wire, which was not visible looking down on it.

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