Plugged in charger after rebuild, hot plastic smell

[Hat Trick]

I hooked all the wiring up and plugged in the charger. Immediately I smelled hot plastic in the front cowl and the cowl near the new headlights was very warm. I unplugged the charger (maybe that was very bad) because I didn't want to start a fire or damage the cart. So suggestions? The charger was reading at 14, nearly pegged. These are brand new batteries, new wiring. I replaced all the cables except the one going through the onboard computer. I tested the lights and they do come on and appear normal brightness. Also, the yellow indicator light is now flashing with nothing on or plugged in.

Help please.

[shadowman]

what did you do to the cart...put new lights in? if so how and did you run your ground to a battery? is this a 48 volt cart or 36 volt and year and model..........if 48 volt did you use a voltage reducer.........just a little more info please..................................

[OLD MEC]

I hope you remembered that on a electric cart ( NOTHING IS GROUNDED TO FRAME ), you need to check all wiring again as hot plastic smell is wiring, switches, reverse buzzer or something else over heating or burning? HOPE you have a fuse between battery pack and any loads, and fuses to blow as protectection for what you are having happen? Like Shadowman says and I hope you didnt run lights off pack voltage rather than 12 volts for all accessories? I know I have forgotten and done just that before?
Wont have anything to do with hot wiring but did you upgrade to 4 gauge wiring and if so you need to run a 4 guage ( around ) OBC as otherwise you have a weak point in your high draw cables just like bending a hose to slow down water flow.

[Hat Trick]

Originally Posted by shadowman

what did you do to the cart...put new lights in? if so how and did you run your ground to a battery? is this a 48 volt cart or 36 volt and year and model..........if 48 volt did you use a voltage reducer.........just a little more info please..................................

Yes, I added lights, new batteries, new motor, controller, solenoid, upgraded to a new HD F/R switch, 4 gauge cables...basically everything is new except the original #18 wiring coming off the key switch/MCOR etc. I DID add a reducer and nothing is grounded to the frame.

This is for a 2002 CC 48 V DS Series cart. So why is this Yellow status indicator light on? Did I damage anything by unplugging the charger during charge cycle?

Here are three pictures. One of the whole battery pack. One of the #1 and #2 batteries in the pack where all my lights and the actual cart charger lead goes to (red wire) and then a pic of the reducer and light relay.







Thanks fellas.

[Hat Trick]

Originally Posted by OLD MEC

I hope you remembered that on a electric cart ( NOTHING IS GROUNDED TO FRAME ), you need to check all wiring again as hot plastic smell is wiring, switches, reverse buzzer or something else over heating or burning? HOPE you have a fuse between battery pack and any loads, and fuses to blow as protectection for what you are having happen? Like Shadowman says and I hope you didnt run lights off pack voltage rather than 12 volts for all accessories? I know I have forgotten and done just that before?
Wont have anything to do with hot wiring but did you upgrade to 4 gauge wiring and if so you need to run a 4 guage ( around ) OBC as otherwise you have a weak point in your high draw cables just like bending a hose to slow down water flow.

Nothing is grounded to the frame. The new Controller came with a huge fuse that is attached that is supposed to protect it and the battery pack. So I need to leave the cable going through the OBC and then run an additional wire (I do have one left over that I suppose is for it) as if it was going through the OBC and hook it up as such?

[BamaDozier]

hat trick... What is that colored spray on your battery terminals?

[Hat Trick]

Originally Posted by BamaDozier

hat trick... What is that colored spray on your battery terminals?

Battery terminal protector. Prevents corrosion.

[Hat Trick]

Anyone see anything from the pics that can help explain what is going on?

[scottyb]

NO....... this is going to be hard for us to find. You have changed EVERYTHING. so the problem could be ANYWHERE

BUt seriously, post a pic of the wiring diagram you used to wire the cart with and a list of parts so we can id everypart... Is that a 16 to 12v 2 wire reducer ?

The yellow low battery light will flash to indicate an incomplete charge if you interrupt the charge cycle, so I think you are safe there. IS every accessory fuse protected at it's power source.... Lights, radio, fan etc?


We are going to need a boat load if info.
P.S. Your best guess ....... where was the smell coming from?

[scottyb]

Check standing voltage at the pack and then at the plug they should be the same and within normal range.
Check to see the fuses are intact behind the charge receptacle. (one big glass fuse and one 3/8th amp fuse in a yellow holder) Check them for continuity