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Old 11-03-2013
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Re: Huge Voltage Drain Problem - Ideas?

You can check the specific gravity of each cell if you have a hydrometer small enough to use the limited electrolyte volume of your Trojan batteries. The sp. gr. of each cell should be within about 5 points of the average (.05).

Wire gauge as small as 16 can carry 40A without damage. Wire insulation damage may not be evident.

You should be looking for a place that a very low resistance to ground has developed…40A at 12V is 0.375 ohms equivalent resistance. You isolated loads and still had the current flowing and that indicates a near-short circuit to ground somewhere.

The best way to isolate something of this nature is to split your distribution system with switches or breakers or fuses while monitoring your instruments until the condition clears…then split the offending half again…and again…until you find the culprit. Near the end you may have to lift leads to isolate the fault.

Good luck.
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