|
Electric Club Car Electric DS, and Precedent golf cars |
|
Thread Tools | Display Modes |
02-21-2011, 05:33 PM | #1 |
Getting Wild
Join Date: Jan 2009
Location: Work or home
Posts: 83
|
Almost new cables, melting problems
I got a new set of 4awg cables a few months ago . Cart had more power after putting them on (old ones were totally junk), but I started smelling a burning odor. Did not think about it again until I was hill climbing yesterday and started smelling it again. Found a hot cable, and then noticed it was melted.
It is a short cable that runs from the motor to the controller. The controller end is fine, but the motor end is melted about 2" up the cable. Should I look for a problem before I replace the cable? Btw: I have a couple extra cables, but they are 1' too long. Would it be safe to use that, or should I get the right size? |
Today | |
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 |
|
02-21-2011, 05:45 PM | #2 |
just leave me alone
Join Date: Aug 2008
Location: Tennessee
Posts: 5,643
|
Re: Almost new cables, melting problems
My guess U have automotive type 4 Gauage , U need High AMP welding cables to handle amp draws up to 300-400 . The higher the thread count the better. Many of the site sponsors sell them !
|
02-21-2011, 05:58 PM | #3 |
Gone Wild
Join Date: Mar 2009
Location: Roseville, CA
Posts: 2,757
|
Re: Almost new cables, melting problems
[QUOTE=mustangless;524146]I have a couple extra cables, but they are 1' too long. Would it be safe to use that,QUOTE]
YES. If these are used cables they will work for now, replace with a new one later. Keep your cables clean tight or this will happen again. |
02-21-2011, 06:13 PM | #4 |
......................
Join Date: Apr 2009
Location: FT Lauderdale FL.
Posts: 16,416
|
Re: Almost new cables, melting problems
When changing the cables on the motor, make sure you use two wrenches, one on the nut at the motor, and one on the nut on top of the cable, make sure the one at the motor does NOT turn
|
02-21-2011, 06:21 PM | #5 |
Getting Wild
Join Date: Jan 2009
Location: Work or home
Posts: 83
|
Re: Almost new cables, melting problems
They are new cables from one of the site sponsors.
Guess that is where I messed up. |
02-21-2011, 06:24 PM | #6 | |
Gone Crazy
Join Date: Jan 2007
Location: Chesterfield, Va
Posts: 6,021
|
Re: Almost new cables, melting problems
Quote:
That's what I was thinking as I read this was the housing stud is loose generating heat. What kind of 4ga cable are you using? where'd they come from? |
|
02-21-2011, 10:23 PM | #7 |
Gone Wild
Join Date: Oct 2010
Location: Panama City, FL
Posts: 1,408
|
Re: Almost new cables, melting problems
|
02-22-2011, 09:26 AM | #8 |
Getting Wild
Join Date: Jan 2009
Location: Work or home
Posts: 83
|
Re: Almost new cables, melting problems
I think this is where I ordered from
http://www.everythingcarts.com/p-202...cable-kit.aspx I learned after trying to put them on I have a regen cart, that is why I have extra cables. are you saying I might have damage inside the motor? |
02-22-2011, 10:01 AM | #9 |
just leave me alone
Join Date: Aug 2008
Location: Tennessee
Posts: 5,643
|
Re: Almost new cables, melting problems
Do U see any damage (arching) on the the lugs where the cables fasten to the motor.
Then yes it's possible. As suggested above , use 2 wrenches when tightening the motor cables. Was the melted cable one going to the motor , or someplace else ? It does not take a lot of arching to melt something at 300-400 amps , this is a big welder. |
02-22-2011, 05:04 PM | #10 |
Gone Wild
Join Date: Oct 2010
Location: Panama City, FL
Posts: 1,408
|
Re: Almost new cables, melting problems
possibly. if only one lug is getting hot, and that lug is properly crimped and fastened tight to the stud, then problem is likely on the other side of the stud. (ie: inside the the motor)
check out the photo below for an example... notice how the wire to the top stud has bent, breaking the weld and is barely hanging on? that little bit of connection left is enough to allow the motor to function, but passing a couple hundred amps through that tiny connection causes massive amounts of heat because a couple hundred amps exceeds the amp carrying capability of the damaged joint. hope that makes sense... again, if everything is tight and proper on the outside and heating is localized to that one joint, its time to look inside. image source: http://server1.buggiesunlimited.com/...p?f=15&t=52823 |
|
|
Similar Threads | ||||
Thread | Forum | |||
what will changing my cables to 4g welding cables do to my performance exactly | Electric EZGO | |||
DCS melting wires | Electric EZGO | |||
Solenoid melting 95 EZ-GO | Gas EZGO | |||
Melting wires???? | Electric Club Car | |||
Heating / Melting Cables | Electric EZGO |