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  #1  
Old 05-17-2010
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SGallaty SGallaty is offline
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Default Battery wiring failure - 85 PT40

My (soon to be my) wlpt40's battery gang wiring burned up.

The CB setup is 6 6v deepcycle golf cart batts, wired in 3 sets of two in series, as you would expect.

The wiring between the batteries in series was 4gauge, and was bolted onto the side-terminal like lugs on the battery tops.

Apparently this worked for a period of time, according to the PO. At some point however, one of the intra-battery wires overheated to a degree that the lug melted and came apart.

I'm guess progressive degeneration from the wiring overheating every time he started the bus.

So, anyhow, question is - does that sound like a reasonable root cause?

Should I be looking further?

What gauge of wires should be going between the 6v batts that are in series? (There are three of these in the entire set)
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Old 05-17-2010
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The_Money_Pit The_Money_Pit is offline
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On my 91 Bird I was having difficult time starting in cold weather. I noticed that my batteries needed replacing, and on closer inspection that my cables were also terribly deteriorated. rusting, and insulation crumbling.

I replaced the batteries, and measured the old wires and went to the locale FleetPride truck parts and had battery cable made from 0, or 1 gauge wire (pretty sure it was 0). Now the engine spins faster than ever.

I have replaced battery wires on autos that melted because of heat. The heat being the result, not the cause. The cause being poor connection, rusted cables, degrading insulation.
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Last edited by The_Money_Pit; 05-18-2010 at 01:42 PM.
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Old 05-17-2010
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Thanks for sharing that. Yeah the PO had 'interstate' come out and wire the batts up, but they used wires insufficient for the application, I think.
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Old 05-17-2010
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JackandLiz JackandLiz is offline
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Quote:
Originally Posted by SGallaty View Post
My (soon to be my) wlpt40's battery gang wiring burned up.

The CB setup is 6 6v deepcycle golf cart batts, wired in 3 sets of two in series, as you would expect.

The wiring between the batteries in series was 4gauge, and was bolted onto the side-terminal like lugs on the battery tops.

Apparently this worked for a period of time, according to the PO. At some point however, one of the intra-battery wires overheated to a degree that the lug melted and came apart.

I'm guess progressive degeneration from the wiring overheating every time he started the bus.

So, anyhow, question is - does that sound like a reasonable root cause?

Should I be looking further?

What gauge of wires should be going between the 6v batts that are in series? (There are three of these in the entire set)
The gauge should be zero or larger. 4 guage is definitely TOO small!!
Good luck with your soon-to-be WL.
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Old 05-18-2010
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where should I go to get these wires fabbed?
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Old 05-18-2010
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The_Money_Pit The_Money_Pit is offline
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truck supply like Fleetpride or similar truck bus supply
http://fleetpride.com/fp_p/index.html

If I had to do it all over again, I would buy the crimper, cable, copper lugs, heat shrink, and either electric grease or battery terminal spray, and do it myself.

cable - might be cheaper to pick up cable locally as shipping may be expensive on heavy cable
http://www.wiringproducts.com/contents/en-us/d78.html

Hammer Style Battery Lug Crimper
http://www.wiringproducts.com/contents/en-us/d41.html

Copper cable lugs
http://www.wiringproducts.com/contents/en-us/d44.html

Heat shrink tubing
http://www.wiringproducts.com/contents/en-us/d81.html
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Old 05-18-2010
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Well, thanks for the info certainly.

These 6v DeepC batteries have both lead lug and threaded lug connectors. Is one more desirable than the other?

Would you put dialectric grease (vaseline) on the terminals?

EDIT: Duh, I see you listed that already.
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Old 05-18-2010
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I rented crimpers from the local rental center. Made it easy. Connect to the threaded post.
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Old 05-18-2010
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Quote:
Originally Posted by SGallaty View Post
Well, thanks for the info certainly.

These 6v DeepC batteries have both lead lug and threaded lug connectors. Is one more desirable than the other?

Would you put dialectric grease (vaseline) on the terminals?

EDIT: Duh, I see you listed that already.
Just had some battery cables made up at a heavy truck parts counter/machine shop. I used 1/0 welding cable (very flexible fine stranded copper) and good heavy lugs. I think they are tin over copper but not certain... definitely appropriate for the use. He used an anti oxidizing compound (consistency of solder flux) on the cable ends before he inserted and double crimped them. Then heavy shrink with glue. Nice cables ... kinda pricey. The 1/0 welding cable alone is $5.60/foot. Worth it to me especially on the FC because they move on the battery slide.

NH Bill
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  #10  
Old 05-18-2010
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Quote:
Originally Posted by SGallaty View Post
Well, thanks for the info certainly.

These 6v DeepC batteries have both lead lug and threaded lug connectors. Is one more desirable than the other?

Would you put dialectric grease (vaseline) on the terminals?

EDIT: Duh, I see you listed that already.

good question, all the batteries that I put in 3 years ago have threaded posts(Sams wholesale club). but not sure if that is the norm. if you don't get an answer here this might be a good question for a new thread. There are some very knowledgeable battery people here.

keep in mind, when you do get new batteries, even though they may be same size, not all manufactures place the posts in the same place. could be off by an inch and those cool cables you had made a year ago no longer fit. - happened to me.
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