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

Re: Heat Problems
 

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.

Re: Heat Problems
 

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

Re: Heat Problems
 

OK now you are asking the hard questions:wink:
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?

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......?

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

Re: Heat Problems
 

might i suggest going to the stickies and printing out the diagram for your cart and just double checking it.........................................8)

Re: Heat Problems
 

Re: Heat Problems
 

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