cart keeps blowing the 60 amp fuse

loungedebaldy55

Hi everyone! I am new to this forum and need help in diagnosing an electrical problem with my ezgo 2005ish electric golf cart. I have blown a couple of fuses now. Batteries are newish and charged and read around 6.26v each. Total coming out is 37.7v. I have looked for bad or faulty wiring but everything looks good. It happened this spring as I was taking the cart out of storage and I had finished cleaning and greasing the bat posts that I noticed that the positive wire would spark like a dead short. I called a repair tech and was told to put the negative wire on last. I did that when I replaced the fuse and it did the same thing only a little less. I went for a ride and the fuse blew about 200 yards away. Obviously there is a problem somewhere. Could someone give me some advise on how to diagnose this problem.. Thanks in advance for any help.
ljb

BGW

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Volt_Ampere

FIrst off it matters not which wire you connect last in a series circuit! (EE 101) Second off a 60 amp fuse isn't going to last on a running cart. You need at least a 200 amp fuse.

JohnnieB

At 37.7V, your battery pack is only about 85% charged. SoC chart attached.

That is an issue that needs to be addressed, but may not be what is blowing the 60A fuse.

Since there is typically no way of knowing if the 60A fuse is blown or not while driving the cart and you said it blew after 200 yards of driving, I'd guess the fuse isn't connected correctly.

Sounds like you have the 60A fuse in the high current circuit (300A or more) that feeds the motor rather than the low current (no more than about 20A) battery charging circuit where it ought to be.

The 8Ga or 10Ga white wire from the charge receptacle should be attached to the 60A fuse on the battery pack's main positive terminal. See attached picture. The main positive terminal in lower right is a bit out of focus, but it is pretty clear that a white wire is connected to the 60A fuse.

If a fuse is used in the high current circuit, it will be a minimum of a 250A fuse. (Stock systems don't have a fuse in the high current circuit)

Attached Images

	JohnnieB's SoC Chart.JPG (63.9 KB, 0 views)
	Before replacing cables 1200x800.jpg (129.6 KB, 0 views)

loungedebaldy55

Thanks for the reply guys and especially for the pics of the bats and charging diagram. I did use a jumper to get the cart home the first time the fuse went so I know the fuse was toast that time. This last time it went we towed it home and I pushed it into the shop so I just assumed the fuse was toast. I can try to jump it again to bypass the fuse to see if it is indeed blown. With the pic I see that it is wired the same as the one on your picture so we know that the wiring is correct. I may add that it is a stock machine and I have done no mods on it. If it is not the 60 amp fuse that is blown then I will check the other fuse. Any other suggestions are appreciated.
ljb

kgsc

If that 60 amp is where it is supposed to be and it is blowing you have an issue in your wires going to the charger port. Also if it blows the activation circuit will not have power because it gets it from the port..

JohnnieB

Oops! I was wrong, you will know if the 60A fuse blows. The cart stops running, unless the reed switch bypass is getting its voltage directly from the battery pack.

If the 60A fuse is wired as shown in the picture and is blowing while driving with no battery charger attached, the heavy black and white wires coming out of the charging receptacle are shorting together somewhere, or the terminals in the receptacle are touching.

Volt_Ampere

As everyone said here that fuse should not be in the power circuit but in the charging circuit only. It will blow easily if it's in the power circuit since you use way more than 60 amps.

Clemsoncartguy

So my charging circuit should have a 60 amp fuse? I don't have one? I have a 96 txt series cart. Can someone link me to RadioShack or ebay sale or somewhere even a sponsor , to the correct charging fuse?

Volt_Ampere

My Yamaha cart has no fuse in the charging circuit. It's a good idea though. The batteries can generate a huge amount of current if you short that plug.

mgray70

You can find them at most any auto parts store like Auto Zone.