Cushman 48v Major Arc

[baseball11jb]

I've got a 2014 Cushman 48v golf cart equipped with a 12v charger box. Origianlly batteries wouldn't hold a charge so got new trojan batteries and replaced them. Right before I replaced the batteries, it started to not want to take a charge. Replaced batteries and then replaced a battery wire (end terminal almost corroded off). When connecting the last wire (negative from charge box to batteries for recharging) it arced big enough at the battery to completely incinerate the terminal end on the wire. Cushman checked my wiring and the batteries and determined all that was correct and said it was a fault in charging box. Replaced charging box and cushman said hook the negative wire first to the battery with the charge wire connector undone at charging box then connect connector with cart in tow and shouldn't have the arc again. Did per their instruction and this time it arced one of the other connectors. Am i missing something here?

[bronsonj]

Baseball11, can you post a pic of your wiring? It sounds like a direct short. The other option is that there are capacitors that are in the controller that will cause a small arc, but nothing that'll vaporize anything. If it vaporizes a wire it's a direct short.