36v txt - new to golf cart building

[terryhx]

i just purchased a lifted 36v ezgo txt . on my first drive i noticed an electrical smell coming from under the seat , i did go up a couple hills so i stopped to let it cool , i drove it around a mile or so round trip and barely got back to my house on a full charge . i drove it again the next day after charging and the same thing happened only it got hotter . so after that drive i parked it and ordered a new f/r switch and heavy 2g cables , after installing all of this i went on another drive and went a little farther but still only around 3 miles tops , again i barely made it home . on my next drive i only went a half mile when i smelled an electrical smell and i raised the seat and saw my f/r switch in flames it melted a lug off the switch that goes to the motor . im needing help and suggestions . im going to use the cart for hunting and i dont really care if it is fast .. i want it to last longer and get more miles as it is 2 miles to the backside of my property .

[disland]

Are the components stock? Clearly you are drawing a lot of current.

[terryhx]

yes all stock .. the only upgrade was the cables and a new f/r switch

[JohnnieB]

Originally Posted by terryhx

i just purchased a lifted 36v ezgo txt . on my first drive i noticed an electrical smell coming from under the seat , i did go up a couple hills so i stopped to let it cool , i drove it around a mile or so round trip and barely got back to my house on a full charge . i drove it again the next day after charging and the same thing happened only it got hotter . so after that drive i parked it and ordered a new f/r switch and heavy 2g cables , after installing all of this i went on another drive and went a little farther but still only around 3 miles tops , again i barely made it home . on my next drive i only went a half mile when i smelled an electrical smell and i raised the seat and saw my f/r switch in flames it melted a lug off the switch that goes to the motor . im needing help and suggestions . im going to use the cart for hunting and i dont really care if it is fast .. i want it to last longer and get more miles as it is 2 miles to the backside of my property .

Originally Posted by terryhx

yes all stock .. the only upgrade was the cables and a new f/r switch

One of these two statements is false.

Lifted carts are not stock.
Lifted carts tend to have taller than stock (18" tall) tires.
Tall tires draw more amps.
If tires are low pressure type, they draw even more amps.

[terryhx]

ok yes it is lifted but the motor and all internals are stock ... im assuming that is what he was talking about since i had already mentioned the lift

[yurtle]

Originally Posted by terryhx

ok yes it is lifted but the motor and all internals are stock ... im assuming that is what he was talking about since i had already mentioned the lift

No, he meant tire size (not wheel size). Larger diameter draws more current - amps.

Another thing that causes excess heat is excess resistance, which means dirty or loose connections. Be careful when tightening battery terminals, as they are almost always lead surrounding a stud, and needs to be tightened in accordance with manufacturer's recommendations, which is inch-pounds, not foot-pounds.

Another possibility is a bad connection between the cable and terminal.

[terryhx]

tires are 22 inch fully inflated and i tightened everything according to specs

[yurtle]

22 inches is a lot larger than stock, 18", which accounts for excess amperage over stock. You will need to upgrade the controller and solenoid, and make sure your new FNR is heavy duty. I melted a stock solenoid and FNR by abusing mine with stock tires and all stock except rear seat.

[yurtle]

How do you plan on using the cart? This will help you decide on what upgrades you'll need now, and down the road if you upgrade to 48 volts.

Passengers? Rear seat? Hills? Paved, gravel or dirt?

FYI, you have a series drive type.

[terryhx]

i will be using it for hunting , moderate hills and yes i will add a rear seat . i would eventually like to upgrade to 48v but cant right now