[jdkskyking]

The investigation continues. 

This post/thread needs attention. If you know anyone with this AC unit please advise them to review this information. 

The light purple ground wire shows signs of corrosion at the connection point near the CB. 
       

The ground wire is also very stiff near the ring connector and along its length for about four inches. 
           

I will be installing a ground buss-bar.

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EYES WIDE OPEN 

   

As I was hunting for the AC Power Supply it hit me that the entire 12v DC “panel board” is literally sitting on the carpet. I’ve got to get an insulator between the power and the combustible carpet. 

   

[jdkskyking]

Heat happens when a connection fails for whatever reason.  It can be corrosion, loss of tension of the connector or a variety of other reasons.  It's one of the reasons simply reseating a connector cures so many problems.  Any discoloration on a connector is a warning of heat and a poor electrical connection.  It's also why I try to use name brand parts instead of chineesium.

It's good you found it, hopefully that cures your problem.

Great information!!!

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Please chime in if you disagree with my initial assessment:

First pass:
Connector problem.
Corrosion with spade connection and wire. 

Resolution:
Verify motor amperage requirements
Verify Proper wire size
Utilize WAGO fasteners for connections. 
Secure wires and connectors to minimize movement during travel. 
Incorporate motor fuse into system, in an accessible location. 
Utilize dielectric grease on all connection associated with the dash air system where possible.

Nice work and I will be going up under my dash to take a look at mine as well. I am glad you are checking the motor amperage, its a good idea since these are most likely brushed motors. Probably would not hurt to go ahead and pull the motors to inspect the brushes and to clean up the commutator while you have it apart. A little oil on the bearings as well will help things out and keep the amperages down.

I need to focus on how the thing comes apart. 

As soon as I have an electrical plan I’ll take a look. 

Somebody has messed around with it. Many missing screws.

[jdkskyking]

My solution…

   

Someday the carpet will be replaced. 

I might… might… be able to raise the panel up a bit. 

I’m done for the day.

One last thing…. 

   

I’ve got a friend that is an electrical engineer… he was not impressed with the ground to wires connection. 

There are two #8 or #10 wires that come out of two relays and join somehow with the main power wire from the CB. That is all wrapped up in tape. I have no option but to investigate that “splice” as well.