Changing battery wires??

Garyjr25 · 11-20-2019, 12:04 PM

May be a silly question but I am going to replace the battery cables on my 04 CC DS 48v. Is there a specific sequence that I should use to remove and replace each cable to avoid possibly damaging anything?

Thanks,
Jr

scottyb · 11-20-2019, 12:31 PM

Yes - Flip the Run Tow switch to the tow position, replace the cables in any order, flip the tow switch to run.

zero26tb4u · 11-20-2019, 01:15 PM

Thank you for asking. I had the same question and we now have an answer.

Thanks Scottyb.

LukeL · 11-20-2019, 04:30 PM

And just be super carefully not to short terminals together while working. It’s way more dangerous than it looks.

scottyb · 11-20-2019, 05:07 PM

Quote:

Originally Posted by LukeL

And just be super carefully not to short terminals together while working. It’s way more dangerous than it looks.

It can be... after many yrs of swapping cables I carelessly dropped a cable into the pack. Murphy's Law ruled and it looped over 2 post in the pack and sparks flew!

The cable ruined both posts before it melted off.

WalterM6 · 11-20-2019, 05:25 PM

Do one at a time. Take an old cable off put a new cable on.

Garyjr25 · 11-20-2019, 09:28 PM

Should I disconnect the main (+) and (-) that goes to the motor while swapping the other cables or does it matter?

Thanks,
Jr

buchrob · 12-04-2019, 04:05 PM

It's a little safer all round if you disconnect both the main cables as you suggested. If you do have an incident, at least the cart's circuitry will be less likely to be involved.

Good idea to replace cables after a while. After 7-8 years of seasonal use/storage, my cart wouldn't click or charge though the individual battery voltages were within tolerance. Previous owner had used cheap cables and green copper corrosion had slowly travelled from the lugs under the insulation to the point that the cables became brittle. Visually they looked ok and tested OK on a small ohm meter, but they obviously couldn't handle a full current load.

I ordered made-to-measure on eBay so that the lugs are nicely sealed.

teecro · 12-04-2019, 06:19 PM

1) Key Switch OFF
2) Run/Tow Switch to TOW
3) Disconnect the Main Negative wire from the battery pack FIRST
4) Reconnect the Main Negative wire to the battery pack LAST

11-20-2019, 12:04 PM	#1
Garyjr25 Not Yet Wild Join Date: Oct 2019 Location: Midwest Posts: 17	Changing battery wires?? May be a silly question but I am going to replace the battery cables on my 04 CC DS 48v. Is there a specific sequence that I should use to remove and replace each cable to avoid possibly damaging anything? Thanks, Jr

11-20-2019, 12:31 PM	#2
scottyb Happy Carting Join Date: Dec 2007 Location: Southern California Posts: 73,406	Re: Changing battery wires?? Yes - Flip the Run Tow switch to the tow position, replace the cables in any order, flip the tow switch to run.

11-20-2019, 01:15 PM	#3
zero26tb4u Not Yet Wild Join Date: Oct 2019 Posts: 50	Re: Changing battery wires?? Thank you for asking. I had the same question and we now have an answer. Thanks Scottyb.
zero26tb4u Not Yet Wild Join Date: Oct 2019 Posts: 50

11-20-2019, 04:30 PM	#4
LukeL Gone Wild Join Date: Jun 2017 Location: Savannah, GA Posts: 6,539	Re: Changing battery wires?? And just be super carefully not to short terminals together while working. It’s way more dangerous than it looks.

11-20-2019, 05:25 PM	#6
WalterM6 Gone Wild Join Date: Apr 2017 Location: SE TN Posts: 2,226	Re: Changing battery wires?? Do one at a time. Take an old cable off put a new cable on.

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11-20-2019, 09:28 PM	#7
Garyjr25 Not Yet Wild Join Date: Oct 2019 Location: Midwest Posts: 17	Re: Changing battery wires?? Should I disconnect the main (+) and (-) that goes to the motor while swapping the other cables or does it matter? Thanks, Jr

12-04-2019, 04:05 PM	#8
buchrob Not Yet Wild Join Date: Feb 2008 Posts: 16	Re: Changing battery wires?? It's a little safer all round if you disconnect both the main cables as you suggested. If you do have an incident, at least the cart's circuitry will be less likely to be involved. Good idea to replace cables after a while. After 7-8 years of seasonal use/storage, my cart wouldn't click or charge though the individual battery voltages were within tolerance. Previous owner had used cheap cables and green copper corrosion had slowly travelled from the lugs under the insulation to the point that the cables became brittle. Visually they looked ok and tested OK on a small ohm meter, but they obviously couldn't handle a full current load. I ordered made-to-measure on eBay so that the lugs are nicely sealed.
buchrob Not Yet Wild Join Date: Feb 2008 Posts: 16

12-04-2019, 06:19 PM	#9
teecro Gone Wild Join Date: Jun 2014 Location: Sunset Bay, TN Posts: 2,390	Re: Changing battery wires?? 1) Key Switch OFF 2) Run/Tow Switch to TOW 3) Disconnect the Main Negative wire from the battery pack FIRST 4) Reconnect the Main Negative wire to the battery pack LAST

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