Smoking under load?, pics attached

hardcorecanuck

Thank You for your advice in notice. I have a 48 volt ezgo and know only a little about the controls for this unit. I do know that under the seat, in the right front corner beside the batteries are all of the controls. The front right unit that is attached to the shifter (F-R) smokes a little when the cart is placed under heavy load. For example loaded up with four people and climbing a hill. Or in the garage when the brake is applied, and i push the pedal down to apply electricity, and hold it there for 20 seconds, i can get the right hand bolt and wire attached to smoke a little, or a lot if i were to hold it for an extended period of time. Is this normal? I have attached some pics. The one that is from above shows the unit that smokes under heavier load, and the zoomed pics are taken from behind the unit, you can see the wire that is melted a litttle on the right of the pics. the bolt it is attached to can get red hot, but not under light load. you can see the metal has been heated. Is this the controller? or is the controller the white box etc. behind this unit? Anyway, is it going to burn out? replace it? if so, wheres the best place to buy parts?

Attached Images

	DSC02149.jpg (38.1 KB, 29 views)
	DSC02155.jpg (24.0 KB, 24 views)
	DSC02156.jpg (39.8 KB, 23 views)

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rusty1

i would replace the f/r selector here is a link to site sponsers they make this board possable so support them please not to mention some give discounts to bgw members
http://http://www.buggiesgonewild.com/site-sponsors.php

pggroves

The cable in the middle pic is toast. Others are too. Time to replace all. Most upgrade to 4ga welding cable.

hardcorecanuck

So, is the unit that the wires are connected to(pic1) just a Forward /reverse selector? that would be the name of the part i would require? Also, replace just the wires going from this unit? or all cables what's the best place to buy these cables?
Thanks

rusty1

yes it is the foward and reverse selector you can get a standard or a heavy duty also i would replace all the big wires on the cart if money premits you could even upgrade to 4 gauge wires all can be purchased throught our sponcers

master66

I ordered my forward and reverse switch assy from Everything carts and they were great as is all the sponsors. You can also buy 4 gauge cable kits for you're application, they come cut in the required length already to replace all the cables from batteries, controller, motor and switch, there are a couple of different site sponsors that carry those.
I my opinion if you at all are thinking of updating the cart at a later time to get more speed or torque I would get the heavy duty version of the forward and reverse switch, this is usually one of the parts you update when going to a larger controller.

master66

Hey Rusty is that you're latest project cart on the avatar ?

rusty1

yep gonna be a 48 v lifted limo cart pulled it in the shop and pulled it out the next day son blowed the motor up in his car he didnt understand that when you check the oil if it was low you have to add some he said it was making a cool clicking sound right before it stoped

master66

Ahhh kids ya gotta love em, well except when they blow something up anyway.

bioniccartsandcustoms

All the advice given has been great. Just remember if you lock the brake and push the pedal down the voltage has to go somewhere. Even with all new heavy duty parts and 4ga. cables, the voltage will find the weakest link in the chain and smoke-it!