Branson 6530C seems to be hot under the hood

[dclt736]

Has anyone noticed that the electrical box on their Bransons get hot? I have owned a 6530C for a few years now, and have had issues with the relays getting very hot. Some to the extent that the plastic relay box shows melting around some wire terminals. Normally I would put that down to excess loads, but considering all the systems are protected by fuses and I don't have to replace fuses, but go through a fair number of relays I wonder if others have seen this. The biggest problem relay was for the AC, but also had issues on the relays for some of the lights. Last year, as a work around, I installed a second fuse/relay box and did a power distribution adjustment by creating more stand alone power circuits for different power draws, including the addition of some LED lighting I had added to the cap. But again this year i have AC issues. I did a load test on the two fan motors and they both draw around 3 AMP on my meter, which didn't seem high to me. Not sure what the compressor clutch would draw, didn't test that. But still the new circuit is showing overheating to the point that it stated to melt the plastic around it. I am going to have the AC serviced this week, to see if they see something I don't, but one thing i do know is that mounting the electric fuse and relay stuff, beside the main exhaust system and above the engine seems to be a very poor design. I would have preferred it to be in the cab area, but understand that the tractor did come without the cab as well. Will add some photos later, but if anyone else has run into this, wonder what solutions you found. Thanks Douglas

 

[K5lwq]

I think you are on to something with exhaust heat. Maybe try some heat shield wrap for your exhaust.

 

[dclt736]

I will look into what i can purchase around here. Not sure how much room there is, and never used anything like this before, will it in any way cause damage to the exhaust system?
Thanks

 

[K5lwq]

It really should't cause any issues. If I had your issue that is what I would try.

 

[5030]

Summit racing has header wrap heat shield and if your motor is turbocharged, wrapping the exhaust manifold may decrease turbo lag and increase power too. Turbo's like hot exhaust gas.

 

[Cougsfan]

Turbo's like hot exhaust gas.

They do to a point. I have been told that if you run a Cummins diesel for extended periods of time over 1300F degrees (if egt is measured on the manifold, 1000F if measured downstream of the turbo) you will fry the turbo. Not sure what it is for a Branson. I have heard of racing turbos reaching 1100C (longivity is less of a concern). So if you wrap your exhaust an egt gauge might be a god investment, and some research on what your turbo will take.

In regards to your problem, the first thing I'd check is for loose wire connections. An infrared thermometer might be of value to quantify what exactly is getting hot, and how hot. On a relay, if the down stream (secondary) side is pulling reasonable amps, that doesn't really say anything about what the upstream (primary) side of the circuit is doing. Perhaps it is letting too much juice through to pull the switch. Another question: is the relay getting hot if the circuit it controls is deenergized? if so their may be a internal short in the primary relay circuit.

 

[K5lwq]

I thought the 6530 was naturally aspirated. However, he only needs to wrap a few inches of the exhaust where it routes close to the relays.

Cougs is correct though and certainly could be a short or weak connection.

 

[dclt736]

Thanks everyone, and yes no turbo on this engine and it is a Cummins as well.
I saw a product on Amazon which is a ceramic blanket, and might be easier to work with then trying to use the small rolls of 2 inch wrap.
I also will do a test on the heat levels with a thermal gun later today as I have some light work to do this evening.
I also really need to see what current is flowing through the AC relay with the system running. But a loose wire terminal is a good point to look at. When i rewire that tractor i used all new terminals but who knows how good they are.

HM&FC 1"x 24"x 31" Ceramic Fiber Insulation Blanket 2400F for QuadraFire Wood Stoves, & More. : Amazon.ca: Home

HM&FC 1"x 24"x 31" Ceramic Fiber Insulation Blanket 2400F for QuadraFire Wood Stoves, & More. : Amazon.ca: Home

www.amazon.ca

 

[K5lwq]

I would use the wrap and not a blanket. You should not need much.

 

[Branson Bob]

Thanks everyone, and yes no turbo on this engine and it is a Cummins as well.
I saw a product on Amazon which is a ceramic blanket, and might be easier to work with then trying to use the small rolls of 2 inch wrap.
I also will do a test on the heat levels with a thermal gun later today as I have some light work to do this evening.
I also really need to see what current is flowing through the AC relay with the system running. But a loose wire terminal is a good point to look at. When i rewire that tractor i used all new terminals but who knows how good they are.

HM&FC 1"x 24"x 31" Ceramic Fiber Insulation Blanket 2400F for QuadraFire Wood Stoves, & More. : Amazon.ca: Home

HM&FC 1"x 24"x 31" Ceramic Fiber Insulation Blanket 2400F for QuadraFire Wood Stoves, & More. : Amazon.ca: Home

www.amazon.ca

If there's a loose wire or connection it could cause (intermittent) arcing which could cause heating without an overcurrent condition. You can measure current in a circuit using a clamp meter IF there's enough exposed length of wire to clamp around.