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Old 11-13-2008, 11:24 PM   #1
StratoGeezer
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Default Freak Trojan Battery Meltdown Incicent

Tonight I experience what I can only describe as a freak accident - that occured as I was upgrading my speed control and installing a HD Solenoid.

While tightening a bolt on the new Solenoid, the wrench slipped and made contact with one of the (disconnected) battery terminals. Sparks flew as I tried to knock the wrench away from the terminal that it touched.

The result - two batteries had terminals melted off of them before I could halt the chaos. See pictures below. You'll also notice that the handle of the socket wrench and one of the terminal bolts became literally welded together.....

So - the first question is - did I just accidently ruin two Trojan batteries in this incident? See pictures below and let me know what you think. Can these terminals be soldered back on? Or are they simply toast?

Thanks...lucky to be here to tell the tale....StratoGeezer



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Old 11-13-2008, 11:47 PM   #2
scottyb
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Default Re: Freak Trojan Battery Meltdown Incicent

You can drill and tap the post...The solenoid may be welded as well?
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Old 11-13-2008, 11:53 PM   #3
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Default Re: Freak Trojan Battery Meltdown Incicent

Always a good idea to insulate your tools when working on sparkies.

Glad no one got hurt!
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Old 11-14-2008, 12:11 AM   #4
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Default Re: Freak Trojan Battery Meltdown Incicent

Quote:
Originally Posted by scottyb View Post
You can drill and tap the post...The solenoid may be welded as well?
Any idea how to tell if the Solenoid got damaged? No visible signs of damage from the outside. It seems the two battery terminals are the only obvious victims so far.

I may try the tapping approach to install new terminals. I'll be lucky to get out of this without forking out for two new batts (at least)....
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Old 11-14-2008, 12:44 AM   #5
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Default Re: Freak Trojan Battery Meltdown Incicent

Solenoid can be tested with a voltmeter...
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Old 11-14-2008, 07:31 AM   #6
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Default Re: Freak Trojan Battery Meltdown Incicent

Powerful little welders we ride around on, eh? The batteries can probably be salvaged, but let's take them OUT of the cart to work on them, OK?

I bet it scared the bugeezus out of you. I know it scared me when it happened to me!
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Old 11-14-2008, 07:44 AM   #7
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Default Re: Freak Trojan Battery Meltdown Incicent

Scared the bejesus out of me - smoke, red hot (and melting) terminals - even some flames.... Then I got really mad at myself for allowing this to happen - although it happend so quickly as most accidents do.... I guess this was my initiation....

Ok - so I'll pull those 2 batts out to work on them - hopefully the only damage is the terminals. I presume I'd drill a fairly shallow hole where the terminal is widest, and screw in a stud (headless bolt) - and just test the battery from there? If I'm lucky that might be all there is to fix, assuming I didn't fry the (brand new $115) Solenoid that I was installing as well.
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Old 11-14-2008, 07:55 AM   #8
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Default Re: Freak Trojan Battery Meltdown Incicent

Quote:
Originally Posted by scottyb View Post
Solenoid can be tested with a voltmeter...
Scotty B - I'm pretty new at this - can you provide me a bit more guidance specifically on how to test the soleniod with the voltmeter to see if it's still ok? What should I look for to ensure it's functional?

Thanks!
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Old 11-14-2008, 11:34 AM   #9
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Default Re: Freak Trojan Battery Meltdown Incicent

Strato solenoids are pretty simple devices and easy to test. There should be 4 terminals, 2 for the coil, and 2 larger ones for the contacts.

Look at it and you should see 2 smaller gauge wires going to the solenoid, these will be the coil that operates from the key switch. The other two terminals will have large wires, one coming from the battery, and the other one is the switched side going to the motor/controller.

First connect your leads across the coil terminals, and operate the key switch. When you turn the key on/off you should see battery voltage applied across the coil as you operate the key switch. Really you don’t even have to use a meter, you should hear it pick up, or put you hand on it and you should feel it.

To test the contacts put one lead of your volt meter on the frame or negative post of the battery assuming it is a negative ground system. Then connect the other lead of the volt meter to the contact terminal coming from the battery. This should read full battery potential regardless of the key position being on/off. Then move the lead to the other terminal going to the motor/controller and operate the key switch. You should see the battery switch on and off with the key.

If you see battery all the time on the output side going to the motor/controller, it means the contacts are welded together. If you do not see any battery it either means there contacts are burned off open, or the relay mechanism has failed.
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Old 11-14-2008, 12:00 PM   #10
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Default Re: Freak Trojan Battery Meltdown Incicent

Gained a little "respect" along the way didn't you. I know I did the first time it happened to me. It happens to everyone. Some worse than others.
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