Melted/Overheated A1 & A2 cables

[weaselorlando]

I have been troubleshooting my G19 cart and found the A1 cable lug was melted off. The motor stud is a little loose too. I am not sure if it was loose enough to cause arcing and melted the lug? I ran a 4 gauge cable I had and the cart is running again. While looking at the other cables , I see that the A2 cable looks like it’s been overheated as well. These are 2 gauge cables that are about 1year old. The cart gets lots of use. Sometimes with a lot of weight. If the cart is running near it’s max load, would you expect heat issues here at these locations? Any ideas? Thanks

Weasel

[cgtech]

That is strange. I would say loose connection, but two?

[smallblock450sl]

looks like a "high speed" motor. What is a lot of weight?

[weaselorlando]

They will occasionally have 4 adults. Maybe 2 of them 200lbs +. Yesterday, after I hooked everything back up, I was moving the cart out of the garage. I had the run/tow switch in the run position and moved the cart 30 feet or so. I felt the A2 cable and it felt warm. When I get back from work, I am going to run the cart and see if I can gather some more data on cable temps. Thanks.


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[Raystar57]

Looking at the second pic where you added the new lower nut you can see the wear on the motor stud nut.
This worn surface was probably not making good contact with the cable and caused the excessive heat to build up.
In the third pic the nut looks worn also.

I really don't think this is a crimp fail.

Replace that cable also and add a new intermediate nut as you did on the first one and I think you will be ok at the motor.

[weaselorlando]

I will give that a try.


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[Raystar57]

If stud breaks or you just want it fixed, since these studs are A1,A2 they are attached to the brush set.
You can replace the set and get new studs.

[weaselorlando]

That sounds like a good option to explore. Thanks


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[weaselorlando]

This is not the stock motor. Any info or advice on changing a brush set for this motor? I do have the service manual to refer to.


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[cgtech]

That is a higher speed motor than stock, and I think you might be overloading it. Also, the procedure for changing brushes is so similar you won't have a problem doing the job.