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Unread 05-22-2008, 01:48 PM   #1
Not Yet Wild
 
Join Date: May 2008
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Unhappy Charging and wiring problem

Our golf cart sat for several months after a cable and connection to the positive side of the battery closest to the driver melted and the post on the battery melted through as well. Several weeks ago I replaced all batteries and replaced all battery wires. Then one morning I woke up to find the charger still "buzzing" and I knew something must be wrong. I disconnected the charger and inspected the batteries and wiring to find one wire starting to melt and it's post also appears to have melted some. I've attached two pics of good looking connections and two pics of the melted one. I need some help...my seven year old daughter is giving me a fit about this!

Two good connections (I had new jumper wires made)...




And the meltdown...


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Unread 05-22-2008, 02:31 PM   #2
nimda
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Default Re: Charging and wiring problem

You either have a bad connection somewhere or something mis-wired. I would say a bad connection somewhere. The good news is you can save those batteries. You can drill and tap the flat part right next to the stud and put a 5/16 stud in.
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Unread 05-22-2008, 02:34 PM   #3
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Default Re: Charging and wiring problem

How can I identify miswiring? I can take and post as many pictures as you want if you can help me.

Is the post damaged too much?
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Unread 05-22-2008, 03:25 PM   #4
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Default Re: Charging and wiring problem

More pics of wiring attached. Any help is appreciated! It's a 1994 model Club Car. The batteries test to 6.45-6.47. Is the battery post OK as long as it's not damaged further or should I tap it now?









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Unread 05-22-2008, 03:46 PM   #5
nimda
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Default Re: Charging and wiring problem

Those wing nuts won't hold up. You need to get regular nuts on those batteries. I built a cart and used wing nuts just like that and ruined my brand new batteries. You cant get them tight enough by hand. The wiring "Looks" in order but you need to get a diagram and be sure.

You should go ahead and drill/tap because once it happens like that they won't last very much longer because the stud is loose.
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Unread 05-22-2008, 09:04 PM   #6
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Default Re: Charging and wiring problem

alas once again crimped connections have struct, or self-destruct. solder is the best connection. crimped connections allow for corrosion, which raises the connection resistance. Over a period of time the bad connection, when used will heat up, sometimes very hot. Its not to difficult to solder the ends of your cables, and they will last quit a bit longer......Burnsamatic tourch and Rosen core solder.
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Unread 05-22-2008, 11:48 PM   #7
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Default Re: Charging and wiring problem

Welcome to the forum timsims...................
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Unread 05-23-2008, 02:51 AM   #8
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Default Re: Charging and wiring problem

Thank You Sir.
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Unread 05-23-2008, 09:06 AM   #9
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Default Re: Charging and wiring problem

In your second post, 1st pic, There is a disconnected wire on the F/R switch. Red & white. Is that grounding out some where? Where did it go? Also charger shouldn't stay on ALL night. A few hours should suffice. Is it an automatic type? Need Pics of the charger face or info tag? Were the batteries warm to touch when the wires melted? You could have a loose connection in the charge circuit? Are thaose battery readings you gave taken 30 minutes after the charger was removed? Also Where is the Blue wire going that is hooked to the battery with the charger white wire?
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Unread 05-23-2008, 09:10 AM   #10
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Default Re: Charging and wiring problem

Quote:
Originally Posted by scottyb View Post
In your second post, 1st pic, There is a disconnected wire on the F/R switch. Red & white. Is that grounding out some where? Where did it go? Also charger shouldn't stay on ALL night. A few hours should suffice. Is it an automatic type? Need Pics of the charger face or info tag? Were the batteries warm to touch when the wires melted? You could have a loose connection in the charge circuit? Are thaose battery readings you gave taken 30 minutes after the charger was removed? Also Where is the Blue wire going that is hooked to the battery with the charger white wire?
Thanks for your efforts with this, scottyb! I will be out of town today but I hope to take pics and answer all of your troubleshooting questions by tonight or tomorrow.
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