Newbie Here: Wires Melting, Sparks - Cart is Dead - Need Help

[billmcewen]

Hi Everyone, I need some help....

I have a 1989 EZGO 36V cart. It's been working great and the kids have been having a blast on it.

My son and I were driving and the cart and all of a sudden it just started loosing all power and died. After it sat for a few minutes it started to go again. The batteries were charged.

The last few days I noticed a burning smell on occasion after the cart had been driven.

A wire coming off the solenoid (I think that's what it is) was very hot and the insulation was starting to melt. I replaced the wire and this time another wire actually melted into the new wire, sparks flew and now my cart is completely dead.

Can someone please give me an idea as to what I did and what I need to do to get up and running again?

I have attached a picture so you could see the wires in question and where they are attached.

Thanks Guys!!!!!

P.S. I used a diagram I found here to add a set of lights and it worked perfectly! Thanks for the help!

[crash12888]

Hey Bill, Not sure about the small wire but the large wire that is getting hot and melting looks to be a $2.00 cable from an autoparts store for a Ford. It will hold it's own on a car but not really made for continous duty use due to the low strand count and the poor crimp on ends.
Need to follow the whole circuit on the small wire to find the short. Where does it go?

[billmcewen]

Originally Posted by crash12888

Hey Bill, Not sure about the small wire but the large wire that is getting hot and melting looks to be a $2.00 cable from an autoparts store for a Ford. It will hold it's own on a car but not really made for continous duty use due to the low strand count and the poor crimp on ends.
Need to follow the whole circuit on the small wire to find the short. Where does it go?

Hey Crash, thanks for your reply. You're right, $5.00 cable...Do I have to use "stranded cable"? Can solid wire be used?

The small wire goes to the back of the unit in the picture. I am sorry I don't know what it is called. I have taken some additional pictures and labeled where the small wire goes. I think these may help.

Thanks for your help!

[pggroves]

Is this a resistor or controller cart?

Upon closer inspection of your pictures, it looks like a resistor cart.

[billmcewen]

Originally Posted by pggroves

Is this a resistor or controller cart?

I believe it is a resistor? Large "coil" in the rear of cart underneath near rear wheel area. Sorry for my ignorance, never had a cart before.

[DOOmsman]

Bill, no problem you are doing good, I can not help on elec carts but it is nice to see someone put up information other than it quit. why? these guys will get you going.

[billmcewen]

Thanks Doomsman. I was trying to give as much info. as I could....I know someone in here will help me figure out what is wrong. Great bunch of guys here!

[pggroves]

It looks like your wiring is not factory.

A pic of the battery bay would be helpful. Also a pic of the accelerator switch (has the solenoid mounted to it) would be helpful as well.

You may want to download/print a wiring diagram and start the task of tracing and verifying all of the control wiring connections.

[DOOmsman]

Bill go to the top of ezgo section and look under basic wiring diagrams you will find some drawings there. A ton of good stuff under stickys.

[billmcewen]

Originally Posted by pggroves

It looks like your wiring is not factory.

A pic of the battery bay would be helpful. Also a pic of the accelerator switch (has the solenoid mounted to it) would be helpful as well.

You may want to download/print a wiring diagram and start the task of tracing and verifying all of the control wiring connections.

PG, maybe these pictures will help. Thanks for your input. It would not surprise me if it is not factory wiring. The cart was used at an apartment complex. My neighbor got it from them and went to replace the brakes and the brakes that are supposed to go on this 1989 cart did not work. It appears the rear end has been changed out to a different year...

Thanks again for your input!