Heat Problems

OleTimer · 10-23-2011, 06:58 PM

I have a 97 CC DS which I have tricked out a bit.
Jakes lift kit with big tires
PlumQuick motor
Altrax 500 amp controller
2 ga Cables
HD Solenoid
HD forward/reverse switch

I have heat problems. 1st problem is the battery. The battery on the far right side gets too hot. The terminals get so hot the terminals unsoldered themselves twice (2 replacement batteries). The new #2 cables on the other batteries stay cool and and the far right on the inboard side still gets hot.

The next problem is the forward/reverse switch, The stock switch got hot, so I replaced it with a heavy duty one. 2 months later the new switch melted. I got a new one. It gets pretty hot too.

I am 60+ years old. My wife and I just drive it around the neighborhood and it is flat (no hills). The cart doesn't get much abuse.

Any thoughts on what may be causing these heat problems?

TIA

Woody

Stevegrmich · 10-24-2011, 05:53 AM

Have you tested the individual cells in the battery that keeps getting hot? Are you sure all connections are clean and tight?

scottyb · 10-24-2011, 08:07 AM

What size big tires
Which PlumQuick motor
Altrax 500 amp controller
2 ga Cables
What make & Size HD Solenoid
HD forward/reverse switch

A little more information will help us determine why you are generating so much heat.

juleshockey6 · 10-24-2011, 08:11 AM

make sure all your cables are tight! and your batteries have water

OleTimer · 10-24-2011, 07:57 PM

OK now you are asking the hard questions

The motor is a PlumQuik Assassin
The controller is a 500 amp Alltrax AXE programmable
The tires are 22x11-10 Sahara Classic
The cables are #2 Welding lead with crimped and soldered lugs
The F/R switch is a heavy duty from Buggies Unlimited
The solenoid is a hard one. I think it came from BU, but it doesn't have any markings that I can see. It is about 2x the size of a stock one and is a maroon plastic contraption.
The batteries are Interstate 8 Volts

The batteries are topped up and kept fully charged. All the electrical connections a fully snugged down. I haven't checked the individual cells in about a month, but the specific gravity has been close to equal on all cells when charged.

I guess that is everything?

scottyb · 10-24-2011, 08:23 PM

IS the battery terminal that melts the one with the white charger wire on it...the same one who's battery cable goes to the solenoid......?

OleTimer · 10-26-2011, 07:21 PM

Well I got a chance the swap the battery cables around. There was no change. This is what I found. It is the negative terminals on 2 right hand batteries. Both heat up, but the forward one heats up the most. It is the right front that I have replaced twice and both time it was the negative terminal that desoldered.

Strangely the F/R switch did not heat up. I wonder what changed?

Woody

shadowman · 10-26-2011, 07:23 PM

might i suggest going to the stickies and printing out the diagram for your cart and just double checking it.........................................

Stevegrmich · 10-26-2011, 07:33 PM

Try moving the batteries to different location and see if problem follows batteries or continues to be same negative cable that heats up . . . this will eliminate battery/batteries as source of issue . . . almost sounds like a short somewhere, or possibly an internal terminal issue in a battery . .

tcb099 · 10-26-2011, 09:11 PM

I'm thinking a bad silinoid but that's just a wag.....

10-23-2011, 06:58 PM	#1
OleTimer Not Yet Wild Join Date: Oct 2011 Posts: 13	Heat Problems I have a 97 CC DS which I have tricked out a bit. Jakes lift kit with big tires PlumQuick motor Altrax 500 amp controller 2 ga Cables HD Solenoid HD forward/reverse switch I have heat problems. 1st problem is the battery. The battery on the far right side gets too hot. The terminals get so hot the terminals unsoldered themselves twice (2 replacement batteries). The new #2 cables on the other batteries stay cool and and the far right on the inboard side still gets hot. The next problem is the forward/reverse switch, The stock switch got hot, so I replaced it with a heavy duty one. 2 months later the new switch melted. I got a new one. It gets pretty hot too. I am 60+ years old. My wife and I just drive it around the neighborhood and it is flat (no hills). The cart doesn't get much abuse. Any thoughts on what may be causing these heat problems? TIA Woody
OleTimer Not Yet Wild Join Date: Oct 2011 Posts: 13

10-24-2011, 08:07 AM	#3
scottyb Happy Carting Join Date: Dec 2007 Location: Southern California Posts: 73,406	Re: Heat Problems What size big tires Which PlumQuick motor Altrax 500 amp controller 2 ga Cables What make & Size HD Solenoid HD forward/reverse switch A little more information will help us determine why you are generating so much heat.

10-24-2011, 08:11 AM	#4
juleshockey6 Not Yet Wild Join Date: Oct 2011 Posts: 66	Re: Heat Problems make sure all your cables are tight! and your batteries have water
juleshockey6 Not Yet Wild Join Date: Oct 2011 Posts: 66

10-24-2011, 07:57 PM	#5
OleTimer Not Yet Wild Join Date: Oct 2011 Posts: 13	Re: Heat Problems OK now you are asking the hard questions The motor is a PlumQuik Assassin The controller is a 500 amp Alltrax AXE programmable The tires are 22x11-10 Sahara Classic The cables are #2 Welding lead with crimped and soldered lugs The F/R switch is a heavy duty from Buggies Unlimited The solenoid is a hard one. I think it came from BU, but it doesn't have any markings that I can see. It is about 2x the size of a stock one and is a maroon plastic contraption. The batteries are Interstate 8 Volts The batteries are topped up and kept fully charged. All the electrical connections a fully snugged down. I haven't checked the individual cells in about a month, but the specific gravity has been close to equal on all cells when charged. I guess that is everything?
OleTimer Not Yet Wild Join Date: Oct 2011 Posts: 13

10-24-2011, 08:23 PM	#6
scottyb Happy Carting Join Date: Dec 2007 Location: Southern California Posts: 73,406	Re: Heat Problems IS the battery terminal that melts the one with the white charger wire on it...the same one who's battery cable goes to the solenoid......?

Today
BGW	Sponsored Links __________________ This advertising will not be shown in this way to registered members. Register your free account today and become a member on Buggies Gone Wild Golf Cart Forum

10-24-2011, 05:53 AM	#2
Stevegrmich Medicare Recipient Join Date: Jun 2011 Location: West Michigan Posts: 3,541	Re: Heat Problems Have you tested the individual cells in the battery that keeps getting hot? Are you sure all connections are clean and tight?

10-26-2011, 07:21 PM	#7
OleTimer Not Yet Wild Join Date: Oct 2011 Posts: 13	Re: Heat Problems Well I got a chance the swap the battery cables around. There was no change. This is what I found. It is the negative terminals on 2 right hand batteries. Both heat up, but the forward one heats up the most. It is the right front that I have replaced twice and both time it was the negative terminal that desoldered. Strangely the F/R switch did not heat up. I wonder what changed? Woody
OleTimer Not Yet Wild Join Date: Oct 2011 Posts: 13

10-26-2011, 07:23 PM	#8
shadowman The Last Moja Morani Join Date: Jan 2007 Location: jumping from cart to cart Posts: 8,975	Re: Heat Problems might i suggest going to the stickies and printing out the diagram for your cart and just double checking it.........................................

10-26-2011, 07:33 PM	#9
Stevegrmich Medicare Recipient Join Date: Jun 2011 Location: West Michigan Posts: 3,541	Re: Heat Problems Try moving the batteries to different location and see if problem follows batteries or continues to be same negative cable that heats up . . . this will eliminate battery/batteries as source of issue . . . almost sounds like a short somewhere, or possibly an internal terminal issue in a battery . .

10-26-2011, 09:11 PM	#10
tcb099 Not Yet Wild Join Date: Aug 2011 Posts: 6	Re: Heat Problems I'm thinking a bad silinoid but that's just a wag.....
tcb099 Not Yet Wild Join Date: Aug 2011 Posts: 6

Thread Tools
Show Printable Version Email this Page
Display Modes
Linear Mode Switch to Hybrid Mode Switch to Threaded Mode

Similar Threads
Thread	Forum
Heat sinks.	Electric EZGO
Cart AC & Heat?	Golf Carts and Parts
Motor heat	Electric EZGO
harnessing the heat..	Electric EZGO