F&R Assembly questions.... Gornoman?

JasonB

Hi all, I have a few questions about my F&R assembly. First the basics...

2003 TXT, 48V conversion, Alltrax 4844, 48V solenoid, 4 ga. wires, HD buss bars.

I did this conversion about three years ago following basically the same set-up that Gornoman did. A couple of weeks ago I started smelling a burning smell and isolated it to the left connection on the back of the F&R assembly (see picture). The connection was only slightly loose (I could rotate the wire in the connection, but not wiggle it). As you can see in the picture, the wire was breaking at the stud and melting the heat shrinking rubber/plastic. I removed the wire and tried to tighten up the contact stud bolt on the back of the contact board, but the contact stud bolt broke. I ordered a new stud, but it sits higher on the contact board than the other three (the new stud itself is thicker), which are flush with the board. Questions...

1) Do the contact studs have to sit flush with the contact board or can they be taller, or sit above the board (if so, I will have to order more studs)?

2) I need a new cam, as the springs are getting weak in the one I have. If I buy a pre-assembled cam, can I get one with the HD bars already installed, or will I have to install the ones I already have on the new cam?

3) Is the probable diagnosis of the original problem most likely the slightly loose connection or could there be another problem area?

4) Finally, on a different subject, I need new batteries and the Energizers at Sam's are priced right. Comments about them? I do have two of them in my current 8 battery set up, but they tend to leak from the top holes. The new ones have the individual screw type caps. Do they prevent leaking better than the old style?

Thanks for the help!

I attached a picture of my cart as well.

Attached Images

	DSCF5461.jpg (82.1 KB, 29 views)
	DSCF0552.jpg (66.6 KB, 29 views)

BGW

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scottyb

You can grind down the stud you bought to be flush, They must be flush or the cam lugs will hang up. What to do depends upon the the condition of your contacts and base plate housing. I make a heavy duty and an ultra cool switch cam. Either one will bolt into your F&R.... Yes, a loose cable could cause all the trouble.

I would suggest a new base and switch cam. That way everything except the Micros are new.

Attached Images

IMG_3872.jpg (57.0 KB, 12 views)

gornoman

My comments in red.

scottyb

24 minute response time Gman, not bad considering the time of night

gornoman

Yeah, but you beat me anyway, AND with better info!

scottyb

Not true, you addressed the weeping batteries

gornoman

Oh, and JasonB, Welcome to BGW!

I really like those wheels!

madoc1

jason, i also have sam's batts am having no probs. the excess moisture maybe as g. said too much water or it could also be that you added them later than your other batts when doing the 48 set up.. then when charging, you wiil be overcharging the new batts because the older ones need the longer charge time to get a full charge. just a theory. jim

JasonB

Thanks for everyone's input. I'll let you know how things turn out.

Jason

ab46501

I tried the Sam's Energizer batteries and they were fine for about two years. I always keep them watered and charged. Run time began to drop off significantly and I replaced with Trojans which are way stronger IMO.