Battery hookup = smoke, electrical experts needed

[CarlG]

My 92 Explorer kept blowing fuses on the turn signal circuit. I finally replaced it with one of the resetting breakers. To my knowledge, in the 5 years since, it has not tripped the breaker even once.

 

[AlanD]

that's an excellent idea

Disconnect the battery first. Take the smaller wire off the starter that feeds the electrical system from the battery. Insert a small 6V bulb if you are a 6V system (12V bulb if 12V) which you have connected alligator clips in series with the connection from the electrical system to the starter terminal. ....

 

[steve s]

... 4) by the time I got the battery disconected the wire insulation was smoking a bit at the stop light switch and at the light switch body at the end of the steering column. ...

Drew,
While it's true that only a large current flow, such as caused by a short, can smoke the wire insulation over the entire wire, a poor connection in a circuit carrying the normal amount of current can cause overheating at the bad contact point, and some of that heat can be conducted up the wire and overheat the adjacent insulation. I would guess that's what was going on in your case.
Steve

 

[Drew N. Minnesota]

Here is what I think and hope was happening with my stop light switch. The insulator was broken and missing under the rear connection on the switch from being over-tightened. This resulted in the attached copper blade being in contact with the copper blade from the front connection and the body of the stop light switch. Please correct me if I'm wrong, but I believe that could account for the brake light being on as well as a short to ground within the switch and the smoking wires.
Either way, I'm going to get the switch fixed and see what happens this weekend while I wait for my battery cutoff switch. If I still see a draw, I will try the light bulb test that jrelliot suggested to see where the problem lies.

 

[H. L. Chauvin]

Hi Drew,

Because you admit that you are a novice, & because you are trying to wire this vehicle by yourself with limited electrical experience, it sounds rather than trying to learn electrical suggestions in a piecemeal fashion, the very first thing that appears to be advised is to obtain:

1. A very good easy to follow printed, "complete" Model A Wiring Diagram with perhaps added notes in reference to "your" particular vehicle.

2. If you do not understand how the electrical system functions on this completed diagram & on your vehicle, it would be a good idea to either self educate yourself by reading electrical wiring basics, or to get some knowledgeable person to explain to you the completed wiring diagram in detail & the wiring of your vehicle to you in detail.

3. You already realize that in not knowing whether or not your switches, & other electrical items & components are junk or are safe & serviceable, that it can be most dangerous to connect everything to a battery to see what works & what smokes.

4. Glad to hear you were able to disconnect the battery prior to maybe burning down your garage or your house, along with the vehicle.


5 . If you learn these simple wiring basics, & I am sure you want to, you will find that none of this is so complicated.

Hope this outlined procedure helps a little.

 

[Tom Wesenberg]

I would start by removing both wires from the cutout, as that will eliminate the generator, cutout, lights and horn from the circuits being powered. Now connect the battery and you should see no sparks if the key and dash light are both turned off. Next connect the generator wire and you should see no spark. Make sure the insulator is in place on the cutout and make sure the screw isn't too long and shorting to the coil inside. If that's OK, then touch the light/horn wire terminal to the cutout screw and see if you get a spark. If no spark then you should be good to install it. If you see a spark with the light switch off, then the horn or lights have a problem.

 

[bogdonj]

I remember when I hooked up my cutout I had the insulator on wrong and it smoked up the wire.. Check to make sure that it's installed right!