melting f/r controler

[grayghost]

I need to pick all the great brains here. I have a 91 marathon it has a 4" lift and used off road. It has a 400 amp Alltrax controller, a high torque motor, #4
wires. After about 10 or 15 minutes of slow driving the forward wires to the f/r controller will get hot and melted the contacts thru the plastic base. All connections are tight and new wires, I talked to Alltrax tech support they said new wires or dirty brushes in motor. I have replaced wires and cleaned brushes still gets hot. Any help would be appreciated.

[scottyb]

Welcome to BGW
I would not suggest this combination of components. Here's why:
Hi torque motor = requires 500- 700 amp control
Hi Torque motor = Requires 2 g cable set
Hi Torque motor = requires HD F&R or better yet, Super duty reversing contactor.

Slow operation keeps the big tired high torque cart in high amperage draw... try going faster for less heat.

[grayghost]

I have what ezgo calls a beefed up f/r. What is the super duty reversing contactor?

[DIRTPIT HC]

cartsunlimited.net You can see them and read up about them there until he posts his much better explanation than mine.

[scottyb]

The directional selection switch in these series carts hasn't changed much (if any) in about 40 years - it's true They are a rotary device where 1 half of the contacts are stationary and the other half rotate using friction contact.

The reversing contactor is a pair of electromagnetic solenoids that make and break these same connections. Go here for more information > http://www.cartsunlimited.net/reversing-contactors.html

[grayghost]

Thank you Scottyb. I went to your web site some very good info there. I will be doing some serious upgrades to my ezgo. I will get in touch with you.