Final battery connect sparks

Datawave · 12-26-2009, 09:55 AM

Firstly, what a fantastic forum and participation.
I just bought a '90 36vdc Club Car from a friend. It was driven to my house from a few blocks down the road. When I took it later in the day it barely had enough power to get it to the charger. The batts were '03 t605's. I put it on charge for close to 12 hours to see if I could get anything out of them. The charger stayed at 25-30 amps. The forward/reverse swith was in forward during the charge, the key was off. I checked the SG and float levels and the batts weren't coming back. I replaced them with a new string of 105's and when connecting the last connection..which was the most positive I get a large spark. If I moved the F/R switch to neutral I can connect. I didn't change any wiring other than the batts. I don't want to ruin the new batts or do any further welding. Am doing something wrong procedurely? I'm afraid I may have shorted the motor during the charge? Any guidance is appreciated.Thanks.

mikesmotortoys · 12-26-2009, 10:09 AM

Does it not run now with the new batteries?

Frizbgolf · 12-26-2009, 10:23 AM

Datawave, there should not be any sparks when you connect the batteries unless there is a load. Even with the switch in the forward position there shouldn't be a load until the pedal is pushed. I would recheck the wiring to see if anything is ground and completing the circuit.

goodoleboy80 · 12-26-2009, 10:39 AM

Sounds to me the solenoid is stuck, letting current pass through. I've got an '89 cc and had the same problem last year.

Frizbgolf · 12-26-2009, 11:51 AM

That is what I was thinking goodoleboy. There has to be something that is letting current pass. I have had a wire that cracked and was touching the frame intermittently kept draining my batts til I found it.

Datawave · 12-26-2009, 12:19 PM

Everything so far is pointing to a shorted motor..when it is brought into the circut is when the problems begin. Any idea what I should be reading between the windings? I have an 87 Fluke.

GLEEMO · 12-27-2009, 11:07 AM

#1 always connect the "-" Negative as the last connection.
The Pos + will always spark when removing from Pack if the - Neg is connected.

"Does it not run now with the new batteries?"
Measure the entire pack ans list Volotage here.
Read this http://www.buggiesgonewild.com/elect...-readings.html

Datawave · 12-27-2009, 01:16 PM

Hooked the most negative last...the cart runs great...thanks to all.

GLEEMO · 12-28-2009, 11:38 AM

NP have FUN

12-26-2009, 09:55 AM	#1
Datawave Not Yet Wild Join Date: Dec 2009 Posts: 5	Final battery connect sparks Firstly, what a fantastic forum and participation. I just bought a '90 36vdc Club Car from a friend. It was driven to my house from a few blocks down the road. When I took it later in the day it barely had enough power to get it to the charger. The batts were '03 t605's. I put it on charge for close to 12 hours to see if I could get anything out of them. The charger stayed at 25-30 amps. The forward/reverse swith was in forward during the charge, the key was off. I checked the SG and float levels and the batts weren't coming back. I replaced them with a new string of 105's and when connecting the last connection..which was the most positive I get a large spark. If I moved the F/R switch to neutral I can connect. I didn't change any wiring other than the batts. I don't want to ruin the new batts or do any further welding. Am doing something wrong procedurely? I'm afraid I may have shorted the motor during the charge? Any guidance is appreciated.Thanks.
Datawave Not Yet Wild Join Date: Dec 2009 Posts: 5

12-26-2009, 10:09 AM	#2
mikesmotortoys Gone Wild Join Date: Mar 2008 Location: Rockwall, Texas (Dallas / Ft. Worth) Posts: 7,077	Re: Final battery connect sparks Does it not run now with the new batteries?
	www.MIKESMOTORTOYS.com www.EZGOPARTSONLINE.com Factory EZGO - Bad Boy Buggy - Dixie Chopper Mowers

12-26-2009, 10:23 AM	#3
Frizbgolf Gone Wild Join Date: Nov 2009 Location: Picayune, Mississippi Posts: 881	Re: Final battery connect sparks Datawave, there should not be any sparks when you connect the batteries unless there is a load. Even with the switch in the forward position there shouldn't be a load until the pedal is pushed. I would recheck the wiring to see if anything is ground and completing the circuit.

12-26-2009, 10:39 AM	#4
goodoleboy80 Getting Wild Join Date: Nov 2008 Location: HARDYVILLE, KY Posts: 81	Re: Final battery connect sparks Sounds to me the solenoid is stuck, letting current pass through. I've got an '89 cc and had the same problem last year.

12-26-2009, 11:51 AM	#5
Frizbgolf Gone Wild Join Date: Nov 2009 Location: Picayune, Mississippi Posts: 881	Re: Final battery connect sparks That is what I was thinking goodoleboy. There has to be something that is letting current pass. I have had a wire that cracked and was touching the frame intermittently kept draining my batts til I found it.

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12-26-2009, 12:19 PM	#6
Datawave Not Yet Wild Join Date: Dec 2009 Posts: 5	Re: Final battery connect sparks Everything so far is pointing to a shorted motor..when it is brought into the circut is when the problems begin. Any idea what I should be reading between the windings? I have an 87 Fluke.
Datawave Not Yet Wild Join Date: Dec 2009 Posts: 5

12-27-2009, 11:07 AM	#7
GLEEMO just leave me alone Join Date: Aug 2008 Location: Tennessee Posts: 5,643	Re: Final battery connect sparks #1 always connect the "-" Negative as the last connection. The Pos + will always spark when removing from Pack if the - Neg is connected. "Does it not run now with the new batteries?" Measure the entire pack ans list Volotage here. Read this http://www.buggiesgonewild.com/elect...-readings.html

12-27-2009, 01:16 PM	#8
Datawave Not Yet Wild Join Date: Dec 2009 Posts: 5	Re: Final battery connect sparks Hooked the most negative last...the cart runs great...thanks to all.
Datawave Not Yet Wild Join Date: Dec 2009 Posts: 5

12-28-2009, 11:38 AM	#9
GLEEMO just leave me alone Join Date: Aug 2008 Location: Tennessee Posts: 5,643	Re: Final battery connect sparks NP have FUN

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