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Unread 06-17-2016, 12:45 PM   #21
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Default Re: Trojan Ranger 160 battery terminals overheating and melting battery plastic

Now that I've seen the pictures it reinforces my idea that you over tightened the lug and broke the lead seal loose causing a bad connection.
Quote:
Done up super tight
I would check all the other battery connections by grabbing the lug and trying to move it side to side. If any are loose repair them. Remember it is only soft lead not steel that they are embedded in.
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Unread 06-17-2016, 01:04 PM   #22
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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.
That is supposed to be actual sizes,...
Attached Files
File Type: pdf WELDING CABLE GUIDE rev.pdf (50.1 KB, 0 views)
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Unread 06-18-2016, 03:57 AM   #23
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Default Re: Trojan Ranger 160 battery terminals overheating and melting battery plastic

This may remain a mystery for now. Cart was going absolutely perfectly today but the lead and terminal coming out of the grey unit were hot after a 10 min run with 5 people in the cart up a hill.

Think I will go for a change in cables just to take this out of the equation. I guess it's not a short as this would blow the fuse. I think it can only be batteries, cables, controller or motor and cables are the easiest to start changing.

Thanks for the advice.
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Unread 06-18-2016, 05:36 AM   #24
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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
... Think I will go for a change in cables just to take this out of the equation. I guess it's not a short as this would blow the fuse. I think it can only be batteries, cables, controller or motor and cables are the easiest to start changing.
First keep in mind that its not the batteries, their size just means they have a bigger reserve. I run the same motor with 500 amp controller and my connections stay quite cool. The difference we can see here is the cables your using are crap and in all likelihood the nut and bolt connections have been over tightened and compromised....
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Unread 06-18-2016, 07:20 AM   #25
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Default Re: Trojan Ranger 160 battery terminals overheating and melting battery plastic

Thanks teecro. I have asked Scotty for some of his good cables. If the connectors have been over tightened is this salvageable?
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Unread 06-18-2016, 07:37 AM   #26
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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
Thanks teecro. I have asked Scotty for some of his good cables. If the connectors have been over tightened is this salvageable?
Remove your cables from the batteries and if there is ANY looseness to the threaded stud in the lead mold these connections will need to be watched closely for the life of the battery. There is the option of salvage as you have already done by way of new lead or a screw-in stud but each is a case by case basis that can only be judged one by one...
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Unread 06-18-2016, 09:20 AM   #27
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Default Re: Trojan Ranger 160 battery terminals overheating and melting battery plastic

OK - I now have a plan. Thanks teecro!
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Unread 06-18-2016, 10:42 AM   #28
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Default Re: Trojan Ranger 160 battery terminals overheating and melting battery plastic

If you want to be proactive and monitor these situations before they become disasters you can do what I do. I once had a bad connection were I had my Alltrax fuse connected and it melted the holder. When I repaired it I placed a piece of un-shrunk heat shrink on the wire. This way every time I look under the seat I can see that heat shrink is still expanded and it didn't get hot.
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Unread 06-18-2016, 01:23 PM   #29
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Default Re: Trojan Ranger 160 battery terminals overheating and melting battery plastic

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Originally Posted by jjance View Post
If you want to be proactive and monitor these situations before they become disasters you can do what I do. I once had a bad connection were I had my Alltrax fuse connected and it melted the holder. When I repaired it I placed a piece of un-shrunk heat shrink on the wire. This way every time I look under the seat I can see that heat shrink is still expanded and it didn't get hot.
That's actually a pretty smart idea
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Unread 06-19-2016, 10:47 AM   #30
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Default Re: Trojan Ranger 160 battery terminals overheating and melting battery plastic

Since my mechanic last patched up a couple of battery terminals the cart is running like a dream with no power fluctuations at all. A couple of the cords only are quite warm but not worryingly hot. Have emailed Scotty for new cables with decent connectors and suspect this will solve the problem, but I'm going to thoroughly recheck all battery terminals and keep checking for excess heat after every couple of runs.

I also found a whitepaper from Trojan on battery connectors which states
"Use two half-thickness lock nuts instead of the standard hex-nut for added
security in applications where high shock or vibration may be encountered.
Do not use a washer or anything that may interfere with the metal-to-metal
contact between the battery terminal post and the cable connector.
Check all connections periodically to make certain that they are and remain
tight. Re-torque if necessary."

I think I have washers from the photos posted earlier, so I probably need to fix this also.

I'm sure this problem is crappy cables and bad battery terminal connections, or maybe the connectors are coming loose with vibration as I have standard small wheels and have on occasion been running the cart ridiculously fast down hill.

Thanks for all of the help and hopefully I have a good plan now.
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