1987 CLub Car DS,(Walle), the Before and After...

[Mooncarter]

Sounds like you have either a bad or a loose cable somewhere.

[LEMANSZ20]

But what cables would cause this? Would any of the red or white ones coming from the forward reverse cause this? Or is it something specific to the black ones connecting each battery to eachother?

I checked the main cable to the motor and that's not getting hot.

[mrgolf]

What gauge wire are the cables made of.? They need to be at least 6 gauge I've seen 8 gauge???

[Mooncarter]

Originally Posted by LEMANSZ20

But what cables would cause this? Would any of the red or white ones coming from the forward reverse cause this? Or is it something specific to the black ones connecting each battery to eachother?

I checked the main cable to the motor and that's not getting hot.

Is it getting hot at the FNR?

[meimk]

I've seen some cables made with heat shrink covering the transition from cable insulation to the metal terminal ends and overlap the contact surface a bit. If any of that insulating sleeve material gets between the cable end and the battery terminal, it will cause problems.

[LEMANSZ20]

Originally Posted by mrgolf

What gauge wire are the cables made of.? They need to be at least 6 gauge I've seen 8 gauge???

I'm not sure, the shop gave me a new pack and I didnt ask. Any way to tell this?

[LEMANSZ20]

Originally Posted by Mooncarter

Is it getting hot at the FNR?

Didnt feel as much, but I'll check it out today, I'll drive it and what I may do is take all the cables connected to the battery and re put them back.

[LEMANSZ20]

I took photos of the ends and it looks like rubber and I guess glue was sticking out on the contacts. I got a little box knife and cut away excess so full contact.

I ran it now and the f&r cables do not get hot, and neither does the cable directly to the motor as well.

The only cables I would say are warm, not scorching hot are the cables connecting each battery. I checked with my hand the batteries and they arent hot at all. So I am just not sure if this is normal for this type of cart or something.

[mrgolf]

That is the problem. The ends need to be clean bare metal clear enough for the whole contact area on nuts and battery post. The cables should not get warm. That glue is causing resistance which causes heat.

The 2 nd photo is not clean enough.

[LEMANSZ20]

Well I cleaned up a few of them and they still got a little warm. I'm gonna recheck them all today and see if that'll solve the issue.

I mean does it matter which side the cables have up or down?