2001 DS 48V melting post on F&R

grandpa1 · 02-15-2015, 11:57 PM

Good evening. I have my son's cart over here today. It has melted the f&r post. This is the second one he has put on here. What is causing this issue?

grandpa1 · 02-15-2015, 11:59 PM

Andy4639 · 02-16-2015, 01:23 AM

99.9% of the time it's a bad connection on one of the ends of the cable are the copper stud is loose are a little of all of them. You need to make sure the F/R copper studs are in good shape and that the right amount of tension is on it when working it back and forth. The studs have to be good and tight not to have a gap between them and the stantionary contacts are it will build up heat and melt.

mrgolf · 02-16-2015, 07:53 AM

That cable end is a good example of what a bad cable end connection looks like..
You need some good golf cart battery cables with good tight ends.

grandpa1 · 02-16-2015, 08:40 AM

OK I will look it over. The f&r was new 2 months ago

CCFanatic · 02-16-2015, 08:54 AM

If the cable in red looked like that before the meltdown, that would be one of the causes. Fix that cable ASAP
IMG_20150215_170320371.jpg

grandpa1 · 02-16-2015, 12:45 PM

OK I will replace it. Also I have found some loose cables on the motor as well. They are loose inside the connector not on the motor lug

CCFanatic · 02-16-2015, 01:01 PM

Make sure all of the connections are nice and tight

grandpa1 · 02-16-2015, 02:50 PM

This may be some of the problem. This electric motor is huge. High speed maybe?

CCFanatic · 02-16-2015, 03:10 PM

That is the GE D380 motor. It is a speed and torque motor. That may be part of the problem. Do some more poking around and see what the controller looks like. Regardless of the controller, I recommend one of ScottyB's HD F-R switches

02-15-2015, 11:57 PM	#1
grandpa1 Gone Wild Join Date: Mar 2013 Posts: 495	2001 DS 48V melting post on F&R Good evening. I have my son's cart over here today. It has melted the f&r post. This is the second one he has put on here. What is causing this issue?
grandpa1 Gone Wild Join Date: Mar 2013 Posts: 495

02-16-2015, 01:23 AM	#3
Andy4639 48/400/Alltrax HS motor Join Date: Jan 2007 Location: Liberty SC, Garden City SC Posts: 6,190	Re: 2001 DS 48V melting post on F&R 99.9% of the time it's a bad connection on one of the ends of the cable are the copper stud is loose are a little of all of them. You need to make sure the F/R copper studs are in good shape and that the right amount of tension is on it when working it back and forth. The studs have to be good and tight not to have a gap between them and the stantionary contacts are it will build up heat and melt.

02-16-2015, 07:53 AM	#4
mrgolf Old Sky Soldier Join Date: Dec 2011 Location: Kentucky Posts: 3,881	Re: 2001 DS 48V melting post on F&R That cable end is a good example of what a bad cable end connection looks like.. You need some good golf cart battery cables with good tight ends.

02-16-2015, 08:40 AM	#5
grandpa1 Gone Wild Join Date: Mar 2013 Posts: 495	Re: 2001 DS 48V melting post on F&R OK I will look it over. The f&r was new 2 months ago
grandpa1 Gone Wild Join Date: Mar 2013 Posts: 495

02-16-2015, 08:54 AM	#6
CCFanatic DS Drivers Club Founder Join Date: Jul 2013 Location: Upstate NY Posts: 3,428	Re: 2001 DS 48V melting post on F&R If the cable in red looked like that before the meltdown, that would be one of the causes. Fix that cable ASAP IMG_20150215_170320371.jpg

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02-16-2015, 12:45 PM	#7
grandpa1 Gone Wild Join Date: Mar 2013 Posts: 495	Re: 2001 DS 48V melting post on F&R OK I will replace it. Also I have found some loose cables on the motor as well. They are loose inside the connector not on the motor lug
grandpa1 Gone Wild Join Date: Mar 2013 Posts: 495

02-16-2015, 01:01 PM	#8
CCFanatic DS Drivers Club Founder Join Date: Jul 2013 Location: Upstate NY Posts: 3,428	Re: 2001 DS 48V melting post on F&R Make sure all of the connections are nice and tight

02-16-2015, 03:10 PM	#10
CCFanatic DS Drivers Club Founder Join Date: Jul 2013 Location: Upstate NY Posts: 3,428	Re: 2001 DS 48V melting post on F&R That is the GE D380 motor. It is a speed and torque motor. That may be part of the problem. Do some more poking around and see what the controller looks like. Regardless of the controller, I recommend one of ScottyB's HD F-R switches

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