Sluggish Starting

Topic: Sluggish Starting (Read 1187 times) previous topic - next topic

Sluggish Starting

June 22, 2020, 09:17:19 pm

Coach was struggling to start fast. Decided to check and clean all of the battery connections. When I went to remove the cable on the negative side the stud was barely hanging on and broke off. The cables in the batteries are molded to the terminals. I will need to order the military grade battery terminals, lugs and 3/0 welding cable.

For now I was able to repair the terminal connection until I can find everything I need to make the cables or have them made. I ground down the broken stud on the terminal, drilled and tapped the terminal to 3/8-16 and made a stud out of a stainless steel 3/8-16 bolt. Inserted the stud into the cable nut till it bottomed out. Cleaned and connected all of the cable connections. Started the coach and it spun like a top.

Now to locate and order everything I need to make new cables. Looking for the military grade battery terminals.

John M.

Re: Sluggish Starting

Reply #1 – June 22, 2020, 09:23:53 pm

Looks like a great repair, could be permanent.

Re: Sluggish Starting

Reply #2 – June 22, 2020, 09:25:08 pm

John I bought some from this place, they were nice cables and fairly reasonable..... shipped fast

Quality Copper Battery Cables Made in the USA! - BatteryCablesUSA

Keith

Re: Sluggish Starting

Reply #3 – June 22, 2020, 09:30:56 pm

I found military grade connectors at a local parts store. So I assume it's something that is standard stock.

Re: Sluggish Starting

Reply #4 – June 22, 2020, 10:34:10 pm

John, here they are at Amazon.
Amazon.com: Ampper Military Spec Battery Terminal End, Top Post Battery...

Lots of less expensive ones there too.

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Re: Sluggish Starting

Reply #5 – June 23, 2020, 02:20:44 pm

Does anyone have a reference for the 3/0 cable. Tried West Marine and the reference Keith posted, no 3/0. Since the cables are going to be very short, can 2/0 be used?
John M.

Re: Sluggish Starting

Reply #6 – June 23, 2020, 02:26:45 pm

John, better to go up in size than down.

Re: Sluggish Starting

Reply #7 – June 23, 2020, 02:51:33 pm

Have you tried a local welding sales shop for the welding cable and terminals? Yes, 4/0 would be better.
Jim

Re: Sluggish Starting

Reply #8 – June 23, 2020, 02:55:14 pm

Quote from: oldguy – June 22, 2020, 09:23:53 pm

Looks like a great repair, could be permanent.

Old Guy,
The main reason I want to make up the cable is that the terminal was hollow and I only have about 3-4 threads due to the wall thickness of the terminal. If it gives out I want to be ready with a replacement.
John M.

Re: Sluggish Starting

Reply #9 – June 23, 2020, 03:40:04 pm

I'm finding out many places are short on supplies due to Covid-19. They say they haven't recieved any supplies in over 7 weeks. I'm going to fly with my current setup. If it fails I will just drill and tap it for the next size up till I find what I need. I think it will hold, just want to be ready in case.
John M.

Re: Sluggish Starting

Reply #10 – June 23, 2020, 06:11:11 pm

Just a Note, these Connectors come in Positive and Negative sizes.... be sure to verify quantity of each That is required. I hate the standard size ones..ones too small, the other too big..
Safe Travels
Dave

Re: Sluggish Starting

Reply #11 – June 23, 2020, 06:50:17 pm

Was able to find everything in the 4/0 size in the above link that Keith posted. Cable in Red and Black, terminal lugs and heat shrink tubing. Going to order everything through them. Question, are the hammer type crimpers good enough to get the job done?
John M.

Re: Sluggish Starting

Reply #12 – June 23, 2020, 07:20:30 pm

I use a hammer crimper no problem. Soldering is best if you have the necessary tools

Re: Sluggish Starting

Reply #13 – June 23, 2020, 07:30:58 pm

No need to give Amazon any money when oriellys cares those military spec battery clamps, not for nothing but I think Bezos has all the money he needs. IMHO.

Re: Sluggish Starting

Reply #14 – June 23, 2020, 07:43:12 pm

TEMCo Industrial Hydraulic Cable Lug Crimper TH0005-11 US TON 6 AWG to 600...
Purchased on June 1. Have tested on two 4/0 ring lugs and was very happy with the result. I've done a lot of aircraft cable ends and this works very good for $105. Would repurchase.
Scott

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Re: Sluggish Starting

Reply #15 – June 23, 2020, 08:02:57 pm

I have one of these FTZ crimpers from Bay Marine
FTZ Heavy Duty Lug Crimp Tool

I have made more than 200 cable ends. I had no luck with a hammer crimper

Re: Sluggish Starting

Reply #16 – June 23, 2020, 08:28:50 pm

When any aircraft needs a cable end, we use a hammer crimper. The only thing different is that a single jack is used instead of the little hammer pictured and it goes in a big shop vice. One shot does the trick. What can you do with a claw hammer but smash a finger? HF has excellent single jacks very inexpensively.
TEMCo Hammer Lug Crimper Tool 5 Year Warranty - Battery Terminal Crimper -...

I solder a lot as I'm usually too lazy to drive 30 minutes to use it. If you use welding cable and solder, support the cable within a few inches of the end.

Pierce

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Re: Sluggish Starting

Reply #17 – June 23, 2020, 08:31:38 pm

John have them build the and ship to you ready to install, I bought some that way, nice quality

Keith

Re: Sluggish Starting

Reply #18 – June 23, 2020, 08:37:15 pm

When I needed to put lugs on the end of a welding cable I used copper lugs. Just put them in a vice, heated them up with butane plumbers torch then filled the hole with solder and then stuffed the cable in. Never had a failure, this was something I was taught in my apprenticeship.

Re: Sluggish Starting

Reply #19 – June 23, 2020, 08:50:45 pm

Quote from: Pierce & Gaylie Stewart – June 23, 2020, 08:28:50 pm

When any aircraft needs a cable end, we use a hammer crimper. The only thing different is that a single jack is used instead of the little hammer pictured and it goes in a big shop vice. One shot does the trick. What can you do with a claw hammer but smash a finger? HF has excellent single jacks very inexpensively.
TEMCo Hammer Lug Crimper Tool 5 Year Warranty - Battery Terminal Crimper -...

I solder a lot as I'm usually too lazy to drive 30 minutes to use it. If you use welding cable and solder, support the cable within a few inches of the end.

Pierce

I've been using a crimp similar to this for 30 years but I got away from the lead cable ends and went to the nickel coated copper,
still using some that I made 20 years ago on tractor
Chris

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Re: Sluggish Starting

Reply #20 – June 23, 2020, 08:58:42 pm

Quote from: Chris m lang – June 23, 2020, 08:50:45 pm

I've been using a crimp similar to this for 30 years but I got away from the lead cable ends and went to the nickel coated copper,
still using some that I made 20 years ago on tractor
Chris

Yes, the nickel coated copper is exactly what the aircraft get.

P

Re: Sluggish Starting

Reply #21 – June 23, 2020, 09:18:14 pm

Cannot imagine not using fire retardant pvc coated marine tinned fine stranded cabling if replacing anything. UL cable and ends.

One in a whatever chance you might need the extra safety. Mark my words. Someone here will have or know of someone who has had a coach fire where the rubber covering supported the fire.

Maybe especially important IF you have a lithium system.

You all probably laugh at me for stressing safety. That's ok. I can live with that. Was in the burn ward once

Re: Sluggish Starting

Reply #22 – June 23, 2020, 09:49:10 pm

Bob,

Can't argue with you as every little protection helps. But unless you build an RV out of Fire Retardant Laminating Resins like commercial hire boats must be constructed with, it's better than nothing. Our RVs with resin, lots of light weight wood are just slow motion bombs waiting for a chance to light up the night sky. Even nasty drywall is light years better and how bout those one hour fire doors? AARP should go on strike or something to make the RV industry go to safer construction. Perhaps sprinklers with a tank on the roof.

https://www.dco.uscg.mil/Portals/9/DCO%20Documents/5p/5PS/Design%20and%20Engineering%20Standards/Life%20Saving%20and%20Fire%20Safety/Docs/ResinList.pdf?ver=2017-10-20-144034-270

Pierce

Re: Sluggish Starting

Reply #23 – June 23, 2020, 09:57:57 pm

I fix what I can. If you have not modded your electrical system you might be somewhat safer. If you doubled or tripled your capacities and added high voltage solar and li batteries i sure would invest the less than $100 needed to have fire retardant cabling put it. It looses less power per foot so less system loss.

My guru buddy recently refused to work on my coach until he found out it still had the 24 volt range rv solar panels he put on it.

He does not think the high voltage stuff is as safe.

Re: Sluggish Starting

Reply #24 – June 23, 2020, 11:13:57 pm

TEMCo Industrial Hydraulic Cable Lug Crimper TH0005-11 US TON 6 AWG to 600...
Starts at 6awg left and goes to 600MCC right and 4/0 in the middle

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