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Electric EZGO Electric EZ GO Marathon, Medalist, TXT and RXV. |
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11-23-2009, 04:26 PM | #1 |
Not Yet Wild
Join Date: Nov 2009
Posts: 10
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Wires heating up
Please bear with me. I have little or no experience with trouble shooting electrical issues. I have a 1995 EZ Go with an upgraded motor. The previous owner installed a Fore-Par motor. The cart's been running fine until just recently. Two of the wires coming from the controller are getting hot enough to melt plastic. One of the wires seems to be coming from the battery (pos) to the controller and the other goes from the controller to the motor (A1 post). We checked the wires for a short/ground thinking that was the problem. All of the wires have been re-shielded and re-routed to protect them from themselves. Also we aren't sure if the motor is grounded properly. I contacted Fore-Par and am still waiting for a call-back from Tech support. One of the other things I was wondering was whether or not the shielding on the windings in the motor has started to break-down creating a resistance issue. Obvious from the way I'm explaining all of this, I'm fairly new to golf cart repair issues. I was just hoping someone here has experienced a similar problem and may be able to assist. Thanks very much for any assistance.
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11-23-2009, 08:45 PM | #2 |
Stay thirsty my friends!
Join Date: Jan 2007
Location: Suburban Chicago
Posts: 24,283
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Re: Wires heating up
ffward, Welcome to BGW!
I would suspect that the cables my be original 6 gauge factory issue. If so, they are beyond their intended lifespan. I would recommend replacing all cables with new 4g welding cable and fresh copper lugs. |
11-23-2009, 10:01 PM | #3 | |
Happy Carting
Join Date: Dec 2007
Location: Southern California
Posts: 73,356
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Re: Wires heating up
Quote:
What gauge are the cables and how old are they ..... they corrode internally and build resistance to the high amperage draw of the upgraded motor |
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11-24-2009, 10:43 AM | #4 |
Gone Wild
Join Date: Aug 2009
Location: Bellingham,WA
Posts: 300
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Re: Wires heating up
ff,
FYI - 6ga wire is .162 diameter (the wire not the insulation) 4ga is .204. Jim |
11-24-2009, 10:52 AM | #5 | |
Gone Wild
Join Date: Mar 2008
Location: Rockwall, Texas (Dallas / Ft. Worth)
Posts: 7,077
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Re: Wires heating up
Quote:
Just a thought from what I see on a daily basis... |
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11-24-2009, 03:13 PM | #6 |
Not Yet Wild
Join Date: Nov 2009
Posts: 10
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Re: Wires heating up
Well, looking at the wire, there seems to be a little corrosion going on. I do have some 2ga wire. It seems like making that change would be harmless. Anything beyond that I think I'd rather have it looked at. Thanks all for the advice. It’s much appreciated.
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