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Unread 06-16-2016, 08:16 AM   #11
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Default Re: Trojan Ranger 160 battery terminals overheating and melting battery plastic

Which is precisely why I didn't write 2(00) or 2/0 awg.
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Unread 06-16-2016, 08:38 AM   #12
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Default Re: Trojan Ranger 160 battery terminals overheating and melting battery plastic

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Originally Posted by NCPW View Post
Which is precisely why I didn't write 2(00) or 2/0 awg.
My apologies for sounding nit picklely... I've seen people misinterpret the commonly confused wire sizes due to not knowing much about the AWG or American Wire Gauge chart....
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Unread 06-16-2016, 12:33 PM   #13
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Default Re: Trojan Ranger 160 battery terminals overheating and melting battery plastic

Scotty looked at the pics and said his cables probably won't solve the problem. I'm now starting to feel small power fluctuations when I'm driving along. Is it possible there is a short somewhere? Has anyone ever had this problem?
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Unread 06-16-2016, 12:59 PM   #14
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Default Re: Trojan Ranger 160 battery terminals overheating and melting battery plastic

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Originally Posted by slobdiddy View Post
Scotty looked at the pics and said his cables probably won't solve the problem. I'm now starting to feel small power fluctuations when I'm driving along. Is it possible there is a short somewhere? Has anyone ever had this problem?
Can you post the fix pics here, maybe they will help somebody explain the cause. Does sound like maybe you have a motor problem now.
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Unread 06-16-2016, 01:38 PM   #15
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Default Re: Trojan Ranger 160 battery terminals overheating and melting battery plastic

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Originally Posted by slobdiddy View Post
Scotty looked at the pics and said his cables probably won't solve the problem. I'm now starting to feel small power fluctuations when I'm driving along. Is it possible there is a short somewhere? Has anyone ever had this problem?
Have you contacted Trojan and could it be covered under warranty?

I looked into the Rangers but the battery dealer had never sold one and I couldn't find anyone at the time who had had one. Maybe it's a good thing I didn't buy them?
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Unread 06-17-2016, 10:21 AM   #16
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Default Re: Trojan Ranger 160 battery terminals overheating and melting battery plastic

Here are the pics - sorry, just with an iPhone and in darkness as I work all day and don't have a garage.

There is a very slight power fluctuation sometimes at full throttle up hill. Possibly more pronounced when it's wet. At this stage I'm worried that the batteries are now damaged as these have been welded to repair them.

I have been feeling the temperature of the battery terminals after cart journeys and this seems mildly warm at worst. I'm worried that this is an intermittent fault which may be impossible to diagnose. I will try again with a full load of 4 people and feel the terminal temperature after.

My mechanic mostly services petrol carts but is a good guy. He says the contacts on the cables may not be good enough and the cable needs to be thicker. Scotty things that the cables may not be the problem.

I don't think I ever upgraded the forward reverse switch, but would have asked about this at the time and this should be ok.

The local Trojan agent denied any liability when I had the initial problem with a terminal burning out, but did provide a replacement battery post which was welded back on by my mechanic.
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Unread 06-17-2016, 10:33 AM   #17
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Default Re: Trojan Ranger 160 battery terminals overheating and melting battery plastic

I am also worried that I may have thrashed the cart down the hills too much and damaged it. There is literally no speed limit down hill and its as fast as you dare go. Wheels standard sized so engine would be spinning pretty fast.
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Unread 06-17-2016, 11:00 AM   #18
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Default Re: Trojan Ranger 160 battery terminals overheating and melting battery plastic

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a replacement battery post which was welded back on by my mechanic.
Did you mean soldered back on?
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Unread 06-17-2016, 11:48 AM   #19
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Default Re: Trojan Ranger 160 battery terminals overheating and melting battery plastic

I thought my mechanic said welded but his English isn't 100% so I'm not sure.
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Unread 06-17-2016, 12:31 PM   #20
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Default Re: Trojan Ranger 160 battery terminals overheating and melting battery plastic

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...I got the existing cables from a reputable dealer...
I hope those cables did not come from any site sponsor, they are pretty sub-standard for Golf Cart application.

While good quality cables likely cannot do anything for that repaired battery, they may prevent other batteries from getting damaged.

Good cables will have a "closed-end" lug where there are no copper strands exposed to acid mist expelled from the batteries.

They will also have heat-shrink tubing that seals the exposed copper between the cable jacket and the lug.

They need to be 5/16 diameter holes to match Golf Cart batteries, not 3/8 like automotive cables.

If the cable is crimped, it needs to use an "Hex" or "Diamond" crimp die, not that split kind you currently have.

If the cable is soldered, it should use "Silver" solder as it has a higher temperature tolerance and lower resistance.

Finally, You should use some kind of anti-corrosive treatment on each battery post after the cables are properly torqued.
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