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Unread 06-14-2016, 12:02 PM   #1
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Default Trojan Ranger 160 battery terminals overheating and melting battery plastic

Hi there.

I recently upgraded my batteries to Trojan Ranger 160s. Excellent performance - really excellent - BUT after about a month one terminal had burnt away and now a few months later I am getting the same problem with several others. The terminals are getting really really hot and the battery plastic is also melting.

I have had new battery terminals welded on to some batteries but want to solve the problem.

I'm running a PQ Executioner motor with an upgraded Curtis controller 1515S 350A (standard is 1515 250A). I also upgraded the cabling (can't remember what gauge but it is heavy duty).

My mechanic has suggested heavier duty battery cables with larger contact terminals so that these make better contact with the battery terminals. Any suggestions for where I can get this type of product? I got the existing cables from a reputable dealer and think I need something a little better than standard heavy duty as it seems to be the contacts that are causing the problem.

My mechanic is competent as he services several hundred golf carts on the island where I live.

Many thanks in advance!
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Unread 06-14-2016, 12:52 PM   #2
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Default Re: Trojan Ranger 160 battery terminals overheating and melting battery plastic

Heat usually comes from resistance of the flow of electricity. Larger cables throughout entire system will likely help.
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Unread 06-14-2016, 02:28 PM   #3
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Default Re: Trojan Ranger 160 battery terminals overheating and melting battery plastic

Quote:
The terminals are getting really really hot and the battery plastic is also melting.
Can You post a close up picture of one of the battery terminals having problems?

Heat develops at the point where the bad connection exists and while better (or proper) cables throughout is a good idea, a bad cable in one place does not cause heat issue in another.

Unless your cables are just getting loose, it may be some improper procedure on the battery terminal connection that is causing the problem.
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Unread 06-14-2016, 06:40 PM   #4
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Default Re: Trojan Ranger 160 battery terminals overheating and melting battery plastic

Has to be a connection (s) or cable problem. I run the same PQ-E motor through a 500 amp controller and drive the cart through some serious hills, hills that a stock 250 amp controller would just not allow me to climb. After many outings I've put my hands all over the cabling and have never felt anything beyond just slightly warmer than ambient in my connections... Only place I have ever felt real heat was the backside of my controller, the heat-sink....
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Unread 06-14-2016, 07:24 PM   #5
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Default Re: Trojan Ranger 160 battery terminals overheating and melting battery plastic

Get a torque wrench and make sure you got them tightened to 100 in/lbs. To much is bad and to little is just as bad. To much and you will bust the lead seat loose.
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Unread 06-14-2016, 08:15 PM   #6
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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
Get a torque wrench and make sure you got them tightened to 100 in/lbs. Too much is bad and too little is just as bad. Too much and you will bust the lead seat loose.
While this is very true I can't tell you how many times I've seen "But I used a torque wrench" in a cry for help with stripped fasteners.... The biggest problem I've encountered is the use of too BIG of a torque wrench on too small of a fastener. Just because the wrench can be set low enough does not make it a suitable choice. NEVER use a torque wrench below 25 % of its scale. IE: If your wrench has a scale of 0 to 100 foot pounds do not use it below 25 foot pounds.
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Unread 06-15-2016, 12:34 PM   #7
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Default Re: Trojan Ranger 160 battery terminals overheating and melting battery plastic

Thanks guys. Think I have 4 gauge cables. Done up super tight. Assume these are getting hot. Cart goes real fast on flats and down hills. This is ruining an otherwise fabulous cart. It must be the cables heating up. I guess it makes sense to try some thicker ones. Is there much difference in cable quality? Any recommendations? I guess cables with larger surface area connectors may also help.

Will try to take some pics tomorrow.
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Unread 06-15-2016, 01:52 PM   #8
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Default Re: Trojan Ranger 160 battery terminals overheating and melting battery plastic

Try 2awg welding cable. Bet it'll solve your problem.

Try Carts Unlimited. Highly recommend his cables plus he's a site supporter.

http://www.cartsunlimited.net/battery-cable-sets.html
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Unread 06-16-2016, 01:07 AM   #9
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Default Re: Trojan Ranger 160 battery terminals overheating and melting battery plastic

Thanks, I have emailed them and will let the forum know if this solves the problem in due course.
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Unread 06-16-2016, 06:23 AM   #10
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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
Try 2awg welding cable. Bet it'll solve your problem.

Try Carts Unlimited. Highly recommend his cables plus he's a site supporter.

http://www.cartsunlimited.net/battery-cable-sets.html
There is a huge difference in 2 AWG (2/0) and 2 gauge.... 2 gauge is what is used in Scotty's kits and that's plenty big...
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