hot positive controller wire

tuukko · 06-01-2010, 10:14 PM

I have an 02 ezgo pds. The positive cable from the battery to the controller gets extremely hot as cart is in use. I tried switching the cables around but the cart will not run. I looked at the diagrams supplied by this site and it seems i have all wires in the proper place. Is there something inside the controller that may be causing the overheating?

Thanks for your help

mikesmotortoys · 06-01-2010, 10:16 PM

How old are the batteries? Is the cart lifted? Is there air in the tires? You tried to switch what wires around?

e-z-go1988 · 06-02-2010, 10:14 AM

Did you just purchase this cart? When did the overheating start? You checked the connections when you swapped the wires so do you have 4ga or bigger wires? Any other components/wiring getting hot?

illushinz · 06-02-2010, 11:38 AM

Quote:

Originally Posted by e-z-go1988

Did you just purchase this cart? When did the overheating start? You checked the connections when you swapped the wires so do you have 4ga or bigger wires? Any other components/wiring getting hot?

/Agree - depending on the amperage passing through the wires, there can be quite a bit of heat dissipation. This condition is exacerbated as the wire size decreases (gauge number increases) or as the voltage/amperage increases.

tuukko · 06-02-2010, 09:39 PM

Quote:

Originally Posted by e-z-go1988

Did you just purchase this cart? When did the overheating start? You checked the connections when you swapped the wires so do you have 4ga or bigger wires? Any other components/wiring getting hot?

I have owned the cart for 4 years. I have been taking the batteries out over the winter months to keep them above freezing and charged. It started overheating last season. I had made new cables for the batteries using 4 ga. welding wire. The positive cable from the controller is the only wire that gets hot (only under load) witch also heats up the white charging wire sharing the same battery post. It got so hot that the lead casing holding the battery threaded terminal started to melt.

Again thanks for you help

tuukko · 06-02-2010, 09:46 PM

Quote:

Originally Posted by e-z-go1988

Did you just purchase this cart? When did the overheating start? You checked the connections when you swapped the wires so do you have 4ga or bigger wires? Any other components/wiring getting hot?

no other components/wiring are getting hot, except for the white charging wire that shares the same battery post with the positive controller wire. When I say I swapped the wires I mean I switched the positive and negative wires with each other to see if I had them backwards since they are not marked positive and negative.

Thank you for your input

06-01-2010, 10:14 PM	#1
tuukko Not Yet Wild Join Date: May 2010 Posts: 3	hot positive controller wire I have an 02 ezgo pds. The positive cable from the battery to the controller gets extremely hot as cart is in use. I tried switching the cables around but the cart will not run. I looked at the diagrams supplied by this site and it seems i have all wires in the proper place. Is there something inside the controller that may be causing the overheating? Thanks for your help
tuukko Not Yet Wild Join Date: May 2010 Posts: 3

06-01-2010, 10:16 PM	#2
mikesmotortoys Gone Wild Join Date: Mar 2008 Location: Rockwall, Texas (Dallas / Ft. Worth) Posts: 7,077	Re: hot positive controller wire How old are the batteries? Is the cart lifted? Is there air in the tires? You tried to switch what wires around?
	www.MIKESMOTORTOYS.com www.EZGOPARTSONLINE.com Factory EZGO - Bad Boy Buggy - Dixie Chopper Mowers

06-02-2010, 10:14 AM	#3
e-z-go1988 Gone Wild Join Date: Mar 2010 Location: Mountaindale, Oregon Posts: 303	Re: hot positive controller wire Did you just purchase this cart? When did the overheating start? You checked the connections when you swapped the wires so do you have 4ga or bigger wires? Any other components/wiring getting hot?

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