SW180 positive terminal getting hot

alangsam · 10-31-2019, 08:53 PM

2018 stretch cc precedent with 18” tires. Alltrax 400 amp,SW180 solenoid and 4ga wire 6 8v batteries and stock amd motor (have the fsip speed motor on order)
With controller allowing 6600 rpm
Could do 28mph with about 100amp continuous per Alltrax software monitoring. Motor was getting hot 200F so scaled it back to 5500 rpm
Max and 25mph. However the solenoid positive terminal is like 175F after a few miles! This solenoid is supposed to handle 200 amp continuous and I am only pulling 100 or less. I have the supplied regen diode installed but not one on the small terminals? Could this be the cause?

Both the positive and negative wires that attach to the large posts on solenoid are very warm although all the rest of the wires between the batteries are not.

The Big Weezy · 10-31-2019, 09:03 PM

Can you provide a picture of the solenoid with the connections please?

Sent from my LG-H910 using Tapatalk

alangsam · 11-04-2019, 09:22 PM

Here are pics of the solenoid wiring.

alangsam · 11-04-2019, 09:26 PM

solenoid wiring

alangsam · 11-04-2019, 09:31 PM

Here are pics of the solenoid wiring.

Sergio · 11-04-2019, 09:45 PM

I had a guess but it is confirmed now that you posted the picture.

The large cable lug must be in direct contact with the Solenoid "nut".

Then put the tow/run ring connector and other smaller wire ring connector(s).

Then put the flat washer and lock washer and finally the other nut.

alangsam · 11-05-2019, 11:53 AM

I will try that - makes sense.

The Big Weezy · 11-05-2019, 01:44 PM

That is what I suspected and why I asked for the pic of your setup.

Sent from my LG-H910 using Tapatalk

alangsam · 11-05-2019, 08:47 PM

Well I reordered the ring terminals per your description. took it out for a run and the terminals are still getting hot - not quite as bad bit still warmer then any other terminals like controller battery or motor terminals. really odd.

Fairtax4me · 11-05-2019, 10:59 PM

Is it the cable or the solenoid itself that’s getting hot? One thing to make sure of with those cable ends is that they are flat and have no knicks or marks from previous installation. If it doesn’t sit perfectly flat on the surface, it will not make a perfect connection and can build heat.
Another possibility is the crimp on the cable is loose or the eyelet or cable end is damaged from previous overheating and needs to have a new eyelet crimped on.

10-31-2019, 08:53 PM	#1
alangsam Getting Wild Join Date: Dec 2015 Posts: 100	SW180 positive terminal getting hot 2018 stretch cc precedent with 18” tires. Alltrax 400 amp,SW180 solenoid and 4ga wire 6 8v batteries and stock amd motor (have the fsip speed motor on order) With controller allowing 6600 rpm Could do 28mph with about 100amp continuous per Alltrax software monitoring. Motor was getting hot 200F so scaled it back to 5500 rpm Max and 25mph. However the solenoid positive terminal is like 175F after a few miles! This solenoid is supposed to handle 200 amp continuous and I am only pulling 100 or less. I have the supplied regen diode installed but not one on the small terminals? Could this be the cause? Both the positive and negative wires that attach to the large posts on solenoid are very warm although all the rest of the wires between the batteries are not.
alangsam Getting Wild Join Date: Dec 2015 Posts: 100

10-31-2019, 09:03 PM	#2
The Big Weezy Getting Wild Join Date: Aug 2016 Location: Illinois Posts: 104	Re: SW180 positive terminal getting hot Can you provide a picture of the solenoid with the connections please? Sent from my LG-H910 using Tapatalk

11-04-2019, 09:22 PM	#3
alangsam Getting Wild Join Date: Dec 2015 Posts: 100	Re: SW180 positive terminal getting hot Here are pics of the solenoid wiring.
alangsam Getting Wild Join Date: Dec 2015 Posts: 100

11-04-2019, 09:45 PM	#6
Sergio Gone Wild Join Date: Sep 2012 Location: Charlotte, NC Posts: 9,329	Re: SW180 positive terminal getting hot I had a guess but it is confirmed now that you posted the picture. The large cable lug must be in direct contact with the Solenoid "nut". Then put the tow/run ring connector and other smaller wire ring connector(s). Then put the flat washer and lock washer and finally the other nut.

11-05-2019, 11:53 AM	#7
alangsam Getting Wild Join Date: Dec 2015 Posts: 100	Re: SW180 positive terminal getting hot I will try that - makes sense.
alangsam Getting Wild Join Date: Dec 2015 Posts: 100

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11-05-2019, 01:44 PM	#8
The Big Weezy Getting Wild Join Date: Aug 2016 Location: Illinois Posts: 104	Re: SW180 positive terminal getting hot That is what I suspected and why I asked for the pic of your setup. Sent from my LG-H910 using Tapatalk

11-05-2019, 08:47 PM	#9
alangsam Getting Wild Join Date: Dec 2015 Posts: 100	Re: SW180 positive terminal getting hot Well I reordered the ring terminals per your description. took it out for a run and the terminals are still getting hot - not quite as bad bit still warmer then any other terminals like controller battery or motor terminals. really odd.
alangsam Getting Wild Join Date: Dec 2015 Posts: 100

11-05-2019, 10:59 PM	#10
Fairtax4me Bonafide Nincompoop Join Date: Dec 2015 Location: Charlottesburg Va Posts: 8,987	Re: SW180 positive terminal getting hot Is it the cable or the solenoid itself that’s getting hot? One thing to make sure of with those cable ends is that they are flat and have no knicks or marks from previous installation. If it doesn’t sit perfectly flat on the surface, it will not make a perfect connection and can build heat. Another possibility is the crimp on the cable is loose or the eyelet or cable end is damaged from previous overheating and needs to have a new eyelet crimped on.

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