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Old 03-11-2023, 04:53 PM   #1
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2002 Monaco Cayman Electrical Problems

I just replaced the four 6 volt house batteries and I'm pretty sure I have wired them together correctly. These batteries test as fully charged, but I am not able to do the following:


Bring in the large front slideout (not enough power).
The smaller rear slide moves but very slowly.
The generator won't start (it just clicks). Also, when I try to start the generator, the 15 amp fuse located in the 12 volt panel box (located in back bedroom) always blows.

Also, the propane furnace very slow to ignite, and blower is running slow.


I have included some pics showing the setups. Does anyone have any ideas?
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Old 03-11-2023, 05:01 PM   #2
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The 15 amp fuse that is blowing is the F2 fuse labeled Living Room.
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Old 03-11-2023, 05:11 PM   #3
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Watching. Thank you.
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Old 03-11-2023, 06:55 PM   #4
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Get a better pix of the 6 vokt battery cabling.

Hard to tell but something don't look right.

There should be 1 terminal, on each battery, with only one cable on it. That cable will go to another terminal with no other cables on it. A positive to a negetive.

Like the top pix.Click image for larger version

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Old 03-11-2023, 07:41 PM   #5
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Get those batteries unhooked !
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Old 03-12-2023, 01:02 PM   #6
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It sounds like you have either wired 6 v or bypassed a pair but still open slides easily. Twinboat has included diagram needed.
But do you have same issue as before you replaced batts often need all the info before being better help. Poster in frustration forgets to include previous issues.
If same issue as old batteries... the following.
Always clean all cable lugs with at least fine wire brush as not scrub all the tin plate off. Is house manual disconnect going bad. You can bypass it. Really clean up battery ground to frame. Any swollen cables or jumpers specifically close to battery from acid and fumes.
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Old 03-12-2023, 04:32 PM   #7
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Measure the voltage on each side of that large solenoid in the back. One probe on a good ground and then test each side and post the measurement.

Are you connected to shoreline???

The reason for checking those posts is that is where each bank comes together and is an easy place to see what is going on.

You should see around 12.5 or more on each side. I could give lots of scenarios but just a couple of measurements should sort things out.

It could be as simple as a dropped wire, a bad battery switch that has failed during the replacement process, or hopefully not having the new batteries wird incorrectly.

Your symptoms are of low voltage of course. It is not important to worry about that blowing fuse just yet. That could just be a symptom and may resolve itself when the batteries are sorted out.
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Old 03-13-2023, 08:57 AM   #8
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Hi everyone, I am helping Rooster40067 work on this Cayman. I will try explain what we have checked so far and the readings we have been getting.
Prior to this new set of 6 volt batteries, both front and rear slide worked properly. And the generator would start fine with a little shot of starter fluid when cold. Prior to this had to have the front power distribution board in compartment under driver side repaired for due to broken solder connections to relays and plugs on the back of the circuit board at a reputable repair shop. While it was there being repaired the house batteries went dead, and the chasis batteries got low and had to be jumped to start the coach. Upon completion of the repair brought the coach home, everything was working fine. A few weeks went by, coach was hooked up to 110 volt so inverter/charger would maintain house battery levels. (Currently there is no 50 amp service available).

Beginning of issues: Began having difficulties with chasis batteries being low and not holding charge. Had to replace both chasis batteries, during this process also house batteries became weak and were not charging to capacity. upon troubleshooting house batteries found them to be very low on water, filled them and attempted to charge them. They would not maintain charge and would loose voltage rapidly when I tried to use any house components. Replaced house batteries, with 230 Ah X 4 golf cart batteries. Vendor I purchased from assured me batteries new are charged to atleast 80%, installed batteries and we had numbered battery connections prior to removal as to reconnect to positions as before removal. Inverter/charger was connected and we charged batteries X 3 days. During this time issues with generator starting appeared, when attempting to start starter solenoid clicks a few times and stops will not crank generator. House lights work and are normal brightness. But house batteries appear to be losing voltage to rapidly. Then, problems with slides developed could not retract slides, when activating switch for rear slide, house living room lights would go out and fuse for living room batteries would blow. 15 amp fuse, after fuse blows slide motors stop working, generator solenoid does not click any more, and living room lights no longer work. When fuse is replaced, when activating rear slide button intermittently, the
50 amp breaker in the bedroom breaker box clicks but does not trip the breaker. If youhold down the slide button the fuse will pop again!!! All house lights work when turned on. As long as you don't attempt to open the slides, now the front slide motor will not even activate at all, (checked power coming to motor it is getting 12.3 volts) when button is pushed. Rear slide motor is activating but very slow and weak and if pressed for extended time the fuse blows again.

Inverter/charger is outputting 14.3 volts when charging in bulk mode to house batteries. Checked voltage at positive and negative cables out to batteries.

Have checked series wiring on house batteries repeatedly and connections appear to
be correct for series. Tried to attach an image to show you but could not attach it.

When charging house batteries positive to positive connections on batteries 3 & 4 read 14.3 volts, batteries 1&2 which are wired negative to negative read 7.3 volts, Batteries 2&4 are positive to negative respectively, and batteries 1&3 are positive to negative respectively, positive from battery switch goes to positive on battery 3, Negative from inverter/charger goes to 2 negative. positive from battery 4 goes to left side of boost solenoid. Positive from charger goes to fuse on back wall, that positive comes out right side of fuse and goes to battery switch on wall, left and right connections on fuse read 14.3 volts when charger is activated. I hope this helps!!!!!!
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Old 03-13-2023, 09:08 AM   #9
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With all the previous info said, Is it possible that all these symptoms are due to low voltage in the system?
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Old 03-13-2023, 09:21 AM   #10
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Drawing of wiring of the house and chasis batteries
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Old 03-13-2023, 09:44 AM   #11
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Good advice posted above. I agree, it is probably a wiring issue, but there are many possibilities.

Start by verifying battery bank wiring as post above.

Next, take a hard look at grounding connections. You may have a heavy cable making poor connection.

The fuse blowing indicates the appliances are trying to draw power through that fuse and small gauge wire. High current through small wire is causing voltage drop at the appliance input. Fuse blows because slide motors draw too much current.

Somewhere a connection is miss-wired or not making good contact. Ground connections often corrode and make poor contact.
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Old 03-13-2023, 12:03 PM   #12
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Correction to previously posted symptoms.

The 15 amp fuse going to the 12 volt living room lights, blows when attempting to start the generator. The solenoid on the generator clicks a few times, then the fuse blows and power is lost to generator starter and the living room house lights. Replace fuse and living room lights will come back on, and solenoid on starter to generator will click again.
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Old 03-13-2023, 12:27 PM   #13
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Quote:
Originally Posted by YC1 View Post
Measure the voltage on each side of that large solenoid in the back. One probe on a good ground and then test each side and post the measurement.

Are you connected to shoreline???

The reason for checking those posts is that is where each bank comes together and is an easy place to see what is going on.

You should see around 12.5 or more on each side. I could give lots of scenarios but just a couple of measurements should sort things out.

It could be as simple as a dropped wire, a bad battery switch that has failed during the replacement process, or hopefully not having the new batteries wird incorrectly.

Your symptoms are of low voltage of course. It is not important to worry about that blowing fuse just yet. That could just be a symptom and may resolve itself when the batteries are sorted out.
Once you get the measurments on these two posts, IF they are not the exact same, check the small posts on the solenoid.

If you have zero volts on either of the small terminals, use a small jumper to apply voltage to the purple wire. You can grab 12 volts from either of the large posts. (Assuming you have 12.5 volts on them).

Doing this should activate the solenoid. With it activated see if any of your symptoms change.

You can get voltage reading that seem fine until under a load such as a starter trying to kick in or a slide trying to activate.

During your battery replacements you could have caused a poor connection to become a bad one.

Those large round posts where wires pile up can look perfectly fine but putting a socket wrench or any wrench you may find they turn a few turns.

Your battery switch could have failed while turning things on and off.

As suggested a bad ground so often bites us, especially if we leave one off.

I really think it should only take a few measurements to sort this out.
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Old 03-13-2023, 04:15 PM   #14
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Quote:
Originally Posted by wjmedic View Post
Correction to previously posted symptoms.

The 15 amp fuse going to the 12 volt living room lights, blows when attempting to start the generator. The solenoid on the generator clicks a few times, then the fuse blows and power is lost to generator starter and the living room house lights. Replace fuse and living room lights will come back on, and solenoid on starter to generator will click again.
You do understand your generator is trying to ground the starter through the lights.
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