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Author Topic: Big Boy 200 Amp Relay  (Read 1259 times)

Lee Welbanks

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Big Boy 200 Amp Relay
« on: June 13, 2018, 07:06:41 PM »
I have removed and cleaned up the relay a couple times and last year I replaced it with a new one when we were up in Maine. So when we came out of Canada the other day the house batteries were not charging so I just ran the gene until we got down here in La Conner.
Removed the relay and sure enough it was all corroded up so I put the old one which I had cleaned up back in the run box, problem solved.
Then I took the relay apart and cleaned it up and in a sealed baggie for the next time.
Lee, Judy  & Pepper
06 Beaver Patriot Thunder
Wilmington IV 40
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Mike Shumack

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Re: Big Boy 200 Amp Relay
« Reply #1 on: June 13, 2018, 07:24:37 PM »
Nice job!
Why are you getting so much corrosion? Is your BB relay mounted in the compartment above the battery box (out of the weather)? Is there any type of seal or o-ring used between the relay cases to keep the moisture out?
- Mike

'05 Beaver Patriot Thunder 525, Vicksburg, CAT C13, Allison 4000MH, HydraLift
Orlando, FL

Joel Ashley

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Re: Big Boy 200 Amp Relay
« Reply #2 on: June 13, 2018, 10:01:54 PM »
I was going to suggest Lexel around the rim, as it’s non-conductive.  But it is flammable, being toluene-based.  The high arc nature of this solenoid might not play well with any fumes trapped inside after it cured.

You’d think there’d be a rubber O ring, but from the pix apparently not.  Not sure what one could use to seal it.  Some solenoids, like are available ignition for our electrical bays, come enveloped in plastic, but how would one do that here ... even plastic dips may be flammable, although plastic epoxys spec sheets I checked don’t say so, and explosivity info isn’t given.  Even Corrosion-X is flammable.  I’d just worry about any product that needs to cure, even painted on the outside of the rim, and vapors being trapped inside the device.

Don’t know about something like Permatex Form-A-Gasket.

Joel

Hmmm... the product claims it’s sealed, so once disassembled that apparently was compromised:
https://www.intellitec.com/assets/pdf/1453-intellitec-pdf-template-53-00507-100.pdf
« Last Edit: June 13, 2018, 10:46:49 PM by Joel Ashley »
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Lee Welbanks

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Re: Big Boy 200 Amp Relay
« Reply #3 on: June 14, 2018, 02:36:57 AM »
Nice job!
Why are you getting so much corrosion? Is your BB relay mounted in the compartment above the battery box (out of the weather)? Is there any type of seal or o-ring used between the relay cases to keep the moisture out?

The relay is mounted in the Intellitec rear run box and is completely high and dry. What kills these relays is that they heat up and cool off, heat up and cool off condensation gets into them. There is a rubber gasket that is supposed to seal the top to the body, next time I have to do this job I'm going to rap the joint between the two pieces with rubberized electrical tap which seals to itself and see if that makes any difference.
Lee, Judy  & Pepper
06 Beaver Patriot Thunder
Wilmington IV 40
525 Cat, 4K Allison
2013 Honda CRV

Mike Tomas

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Re: Big Boy 200 Amp Relay
« Reply #4 on: June 16, 2018, 05:23:48 PM »
"The relay is mounted in the Intellitec rear run box and is completely high and dry"

Maybe you can find some room in the run box to put in some desiccant packages to help control the humidity?

https://www.amazon.com/Hydrosorbent-OSG-40-Dehumidifier-Desiccant-Chloride/dp/B015OT106O/ref=sr_1_5?ie=UTF8&qid=1529166169&sr=8-5&keywords=desiccant
-Just my .02¢ of input. -Not to be confused with the $2.00 input from others.

[]\/[]Tomas
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Jerry Emert

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Re: Big Boy 200 Amp Relay
« Reply #5 on: October 10, 2019, 02:27:46 PM »
Old post I know but same subject!  I'm probably going to have to take apart and clean my Big Boy relay.  It looks pretty straight forward but one question?  The description of the relay says that they use a unique anti-oxident to protect the contacts. There are several anti-oxidant and dielectric greases available. For those that have rebuilt the relay, what coating, if any, have you used?  Thanks in advance.
Jerry, Chief USN Retired
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Mike Shumack

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Re: Big Boy 200 Amp Relay
« Reply #6 on: October 10, 2019, 03:10:16 PM »
The rebuilding instructions I have say to use "CAMCO Electrical Protectant" and Lube (avail at Amazon). https://www.amazon.com/Camco-55013-PowerGrip-Electrical-Protectant/dp/B0024E71JI  - at least that is what the person rebuilding his Big Boy used.

I have the instructions, but too big to attach here at 567KB



- Mike

'05 Beaver Patriot Thunder 525, Vicksburg, CAT C13, Allison 4000MH, HydraLift
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Jerry Emert

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Re: Big Boy 200 Amp Relay
« Reply #7 on: October 10, 2019, 04:23:33 PM »
The rebuilding instructions I have say to use "CAMCO Electrical Protectant" and Lube (avail at Amazon). https://www.amazon.com/Camco-55013-PowerGrip-Electrical-Protectant/dp/B0024E71JI  - at least that is what the person rebuilding his Big Boy used.

I have the instructions, but too big to attach here at 567KB
Please email. I believe you have it.  Thanks.
Jerry, Chief USN Retired
2003 Patriot Thunder Lexington 40' 3 Slides
C-12 Ser#  2KS89983
4000MH

Mike Shumack

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Re: Big Boy 200 Amp Relay
« Reply #8 on: October 10, 2019, 04:39:02 PM »
I tried your e-mail previously and it didn't work (I know the ending part of the address, but the first part using "Jerry"
 didn't work.
- Mike

'05 Beaver Patriot Thunder 525, Vicksburg, CAT C13, Allison 4000MH, HydraLift
Orlando, FL

Jerry Emert

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Re: Big Boy 200 Amp Relay
« Reply #9 on: October 10, 2019, 04:51:46 PM »
sent a text.
Jerry, Chief USN Retired
2003 Patriot Thunder Lexington 40' 3 Slides
C-12 Ser#  2KS89983
4000MH

Stan Simpson

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Re: Big Boy 200 Amp Relay
« Reply #10 on: October 10, 2019, 04:55:19 PM »
Mike Shumack - Could you email me those instructions as well, please?

therealsimpsons@mail.com

Thank you.

Stan
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Mike Shumack

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Re: Big Boy 200 Amp Relay
« Reply #11 on: October 10, 2019, 05:07:06 PM »
Sent
- Mike

'05 Beaver Patriot Thunder 525, Vicksburg, CAT C13, Allison 4000MH, HydraLift
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