First cart

[radioman]

Don't get burned feeling around for hot connections. Put a few drops of water on each big terminal on the solenoid and see which side produces steam.

[rsuddeth]

Thank you. I will check it this weekend. Could it be a bad solenoid?

[yurtle]

Is the whole cable hot or just one or both terminals? Probably have a bad lug or two. The amperage is the same through all of the cables, so they should all be the same temp.

If you have a bad lug, in the short term, you could put a new lug on the existing cable, assuming the copper strands aren't too corroded. That's what I did on several of mine while waiting to upgrade.

[radioman]

It could be. After you run it a little while see which gets warm, the battery connection or the solenoid end. The solenoid might have a contact or wire crimp bad on the battery side. Your recently charged batteries just made the fault get hotter. If you have access to a hand held temperature measuring device you can use it to locate hot connections. A slight bad connection can get red hot on the high current flow through it. Don't get burned.

[JohnnieB]

Originally Posted by rsuddeth

JohnnieB: Here are pics of the charger. What do you think?

You've got some cable/connection issues and your Powerise charger may not be fully charging you new US2200 batteries.

Be careful tightening the nuts on the battery studs. 10 ft/lb is max torque on them.
The studs are actually hex-head bolt embedded in the lead post, and too much twisting force will distort the lead, which will cause a hot spot and may melt the battery post.

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What is the At-Rest voltage of the battery pack and the individual batteries?
At-Rest voltage is measure 12 hours after the batteries have been charged.
I posted a chart earlier tell what they should be.

[rsuddeth]

JohnnieB, I got 6.4 volts individually and 38 volts together, so looking good there. The wire wer hot at the terminal on both positive and negative side, so I replaced the terminal ends. Huge difference even though the wires have corrosion all the way through the wire. Guess a full blown 2 guage wire set up is in the future.

[JohnnieB]

Originally Posted by rsuddeth

JohnnieB, I got 6.4 volts individually and 38 volts together, so looking good there. The wire wer hot at the terminal on both positive and negative side, so I replaced the terminal ends. Huge difference even though the wires have corrosion all the way through the wire. Guess a full blown 2 guage wire set up is in the future.

Be sure to replace all 13 high current cables.

[rsuddeth]

Okay, back at it. I will order enough welding cable to all 13 cables this week. Next, I want tot sort out then front end. It is very sloppy. What do I replace? Tie rod ends, bearings , etc. ????