Melting battery cables

[Jspillis]

My 95 48v. Club car runs well but melts battery cables and terminals. All connections are tight. Any suggestions?

[gaminde]

Resistance = heat
tight maybe making good contact no

[Larry1950]

Agree.
What gauge are the battery cables? Are you melting all or just one. Are the battery and cable connections clean? Something is drawing way too much current.

[Jspillis]

Agree.
What gauge are the battery cables? Are you melting all or just one. Are the battery and cable connections clean? Something is drawing way too much current.

Cables are 4 gauge. Melted the pos terminal and the neg cable on the 48v connections. Agree, something is drawing way too much current. But what?

[Larry1950]

Wow! The connection at the positive must be corroded and or loose. Is the solenoid getting hot? I would make sure all connections at the batteries, solenoid, controller, OBC are clean and tight.
I take it the Negative cable going to the OBC is melting. According to the wiring diagram the negative and positive are located very close to each other at the controller, make sure the wires are not loose or touching and are tight and clean

http://www.golfcartsforum.com/attachments/golf-cart-diagrams/102d1233969106-club-car-ds-95-48v-wiring-diagram-95_95-5_club_car_48v_wiring_diagram.jpg

[Jspillis]

Larry, thanks for the suggestions. The neg cable at the controller was arcing onto pos cable from the solonoid. On completion of test run, neg terminal hot, cable from solonoid warm, all other terminals cool. ?

[Larry1950]

Sound like you have found most the problems. Need to find out why the negative term is hot. Still some resistance there somewhere, most likely at the Negative term. Wire brush time for nice shinny terminals.

[Jspillis]

Swapped batteries. Took long test run up and down hills. Everything cool. Must have been a terminal problem as well. Thanks for all the help. Talk to you next time something goes wrong.

[Larry1950]

Glad it was a simple and cheap fix.