A lot of smoke, but no fire.

jpeezy · 10-15-2008, 03:09 PM

I just replaced the battery cables on my '87 marathon 36v with 4g wires and the resistor coil wiring with 6g wires. Now every time the key turns on the wiring off of the fnr switch starts smoking and melting. The cart had 6g on the batteries prior. Do I need to go either 4g all the way through or is there some other problem?

roady89 · 10-15-2008, 03:13 PM

Go over your wiring again, you miswired something when you changed the cables.

jpeezy · 10-15-2008, 03:20 PM

I did bypass the back up buzzer by putting a jumper between the micro switches. But I didn't think that it was a big deal. Was I wrong? Also it seems like the heat is coming off of the m-switches.

roady89 · 10-15-2008, 03:24 PM

If you jumped the backup buzzer micro the buzzer would sound ALL the time. I don't think you jumped the backup buzzer micro, must have been something else. My next question is "Did the cart run before you rewired it?"

jpeezy · 10-15-2008, 03:30 PM

Yes, it ran. I took the two wires from the m-switches that went into the buzzer, cut them off the buzzer, and tied them together. The cart goes f and r now, but with smoke from the fnr switch.

roady89 · 10-15-2008, 03:35 PM

Tieing the 2 buzzer wires together should create a dead short ONLY when you place the cart in REVERSE. Those 2 wires should not have any effect on anything else unless someone has canabalized the wiring and has it all messed up. You should get a wiring diagram and make sure everything is correct before something catches fire.

jpeezy · 10-15-2008, 03:44 PM

Ok, thnx roady. The cart didn't work when a guy down the street put it out on the curb with a "take me" sign on it. So I drug it home for my first cart project. I got it running with some batteries and cleaning, and now I'm just replacing parts as I get some extra money. The wiring seems correct by the diagram I got, other than that buzzer. My problem seemed to start with replacing the battery cables with 4g instead of the 6g it had before.

Texasworkhorse · 10-15-2008, 04:57 PM

I installed 4 AWG gauge cables on my 1987 resistor cart without any problems pre or post cable install. I'm sure I'm not the only one. I did draw out the cabling prior to disconnecting everything. Sounds like a loose connection or miswiring..........

10-15-2008, 03:09 PM	#1
jpeezy Not Yet Wild Join Date: Oct 2008 Location: Las Vegas, NV Posts: 9	A lot of smoke, but no fire. I just replaced the battery cables on my '87 marathon 36v with 4g wires and the resistor coil wiring with 6g wires. Now every time the key turns on the wiring off of the fnr switch starts smoking and melting. The cart had 6g on the batteries prior. Do I need to go either 4g all the way through or is there some other problem?

10-15-2008, 03:13 PM	#2
roady89 nimda Join Date: Jun 2007 Posts: 13,023	Re: A lot of smoke, but no fire. Go over your wiring again, you miswired something when you changed the cables.
roady89 nimda Join Date: Jun 2007 Posts: 13,023

10-15-2008, 03:20 PM	#3
jpeezy Not Yet Wild Join Date: Oct 2008 Location: Las Vegas, NV Posts: 9	Re: A lot of smoke, but no fire. I did bypass the back up buzzer by putting a jumper between the micro switches. But I didn't think that it was a big deal. Was I wrong? Also it seems like the heat is coming off of the m-switches.

10-15-2008, 03:24 PM	#4
roady89 nimda Join Date: Jun 2007 Posts: 13,023	Re: A lot of smoke, but no fire. If you jumped the backup buzzer micro the buzzer would sound ALL the time. I don't think you jumped the backup buzzer micro, must have been something else. My next question is "Did the cart run before you rewired it?"
roady89 nimda Join Date: Jun 2007 Posts: 13,023

10-15-2008, 03:30 PM	#5
jpeezy Not Yet Wild Join Date: Oct 2008 Location: Las Vegas, NV Posts: 9	Re: A lot of smoke, but no fire. Yes, it ran. I took the two wires from the m-switches that went into the buzzer, cut them off the buzzer, and tied them together. The cart goes f and r now, but with smoke from the fnr switch.

Today
BGW	Sponsored Links __________________ This advertising will not be shown in this way to registered members. Register your free account today and become a member on Buggies Gone Wild Golf Cart Forum

10-15-2008, 03:35 PM	#6
roady89 nimda Join Date: Jun 2007 Posts: 13,023	Re: A lot of smoke, but no fire. Tieing the 2 buzzer wires together should create a dead short ONLY when you place the cart in REVERSE. Those 2 wires should not have any effect on anything else unless someone has canabalized the wiring and has it all messed up. You should get a wiring diagram and make sure everything is correct before something catches fire.
roady89 nimda Join Date: Jun 2007 Posts: 13,023

10-15-2008, 03:44 PM	#7
jpeezy Not Yet Wild Join Date: Oct 2008 Location: Las Vegas, NV Posts: 9	Re: A lot of smoke, but no fire. Ok, thnx roady. The cart didn't work when a guy down the street put it out on the curb with a "take me" sign on it. So I drug it home for my first cart project. I got it running with some batteries and cleaning, and now I'm just replacing parts as I get some extra money. The wiring seems correct by the diagram I got, other than that buzzer. My problem seemed to start with replacing the battery cables with 4g instead of the 6g it had before.

10-15-2008, 04:57 PM	#8
Texasworkhorse Not Yet Wild Join Date: Oct 2008 Posts: 49	Re: A lot of smoke, but no fire. I installed 4 AWG gauge cables on my 1987 resistor cart without any problems pre or post cable install. I'm sure I'm not the only one. I did draw out the cabling prior to disconnecting everything. Sounds like a loose connection or miswiring..........

Thread Tools
Show Printable Version Email this Page
Display Modes
Linear Mode Switch to Hybrid Mode Switch to Threaded Mode

Similar Threads
Thread	Forum
Smoke - 1991 Ez-Go Marathon 3PG	Gas EZGO
White Smoke	Gas Club Car
18hp blowing black smoke	Big Block Talk!
Fire, smoke and other stupidity	Electric Club Car
No Fire	Big Block Talk!