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Unread 10-23-2011, 07:58 PM   #1
Not Yet Wild
 
Join Date: Oct 2011
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Default 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
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Unread 10-24-2011, 06:53 AM   #2
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Default 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?
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Unread 10-24-2011, 09:07 AM   #3
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Default 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.
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Unread 10-24-2011, 09:11 AM   #4
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Default Re: Heat Problems

make sure all your cables are tight! and your batteries have water
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Unread 10-24-2011, 08:57 PM   #5
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Default 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?
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Unread 10-24-2011, 09:23 PM   #6
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Default 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......?
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Unread 10-26-2011, 08:21 PM   #7
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Default 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
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Unread 10-26-2011, 08:23 PM   #8
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Default Re: Heat Problems

might i suggest going to the stickies and printing out the diagram for your cart and just double checking it.........................................
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Unread 10-26-2011, 08:33 PM   #9
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Default 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 . .
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Unread 10-26-2011, 10:11 PM   #10
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Default Re: Heat Problems

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