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Unread 05-13-2015, 09:35 PM   #1
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Default Battery terminals over heating

Hey guys,

I need so help. I have a 2001 Club Car Transporter 6 DS. Last summer I put a lift kit and the high torque beast motor with ne controller, HD switch, 4 gauge wire as was supplied in the kit, new 8 volt batteries,etc. So I'm just getting it out of the snowed in shed...

I am having problems with the 5/16" studs on the batteries overheating and melting the lead away (lead melts at 621 degrees F). The 1st one I figured I just had not tightened it up. When the 2nd one failed I removed all the wires and cleaned everything up and then installed a one nut all the way down and then placed the terminal on and the another nut (jam nut) on top so it would be as tight as I could get it. Last night it melted two more studs!!!! Tonight I removed all of the connections and filed them so there is no corrosion and applied dielectric grease to the all.

If it fails again I'm out of ideas... Anyone have any issues like this before?

I took a couple of pics but I don't know how to attach them.

Thanks, Doug
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Unread 05-13-2015, 10:23 PM   #2
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Default Re: Battery termoinals over heating

The "jam" nut is not a good idea.

The threaded post on those battery terminals are only designed to keep a tight connection between the copper cable lug and the lead surface of the battery post.
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Unread 05-13-2015, 11:00 PM   #3
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Default Re: Battery termoinals over heating

Bad connections are causing this! They are either dirty or loose. The bad connection could be between the lug and the battery post or between the cable and the lug.
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Unread 05-14-2015, 10:01 AM   #4
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Default Re: Battery terminals over heating

Look for corrosion wicking up into the cables as well. BTW, what controller? Are you pulling long hills, flat out with a full load for several minutes at a time?
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Unread 05-14-2015, 03:49 PM   #5
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Default Re: Battery terminals over heating

Might be a dumb question but are the actual battery terminals loose within the lead post? That happens with over tightening and over time, think of an upside down bolt within the battery terminal itself.
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Unread 05-14-2015, 05:02 PM   #6
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Default Re: Battery termoinals over heating

Quote:
Originally Posted by Volt_Ampere View Post
Bad connections are causing this! They are either dirty or loose. The bad connection could be between the lug and the battery post or between the cable and the lug.

I agree. I would check those cables you mentioned. All cables aren't created the same. Either make some or replace them with some from a reputable vendor and I'll bet your problems will be solved.
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Unread 05-14-2015, 06:34 PM   #7
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Default Re: Battery terminals over heating

It's probably the cables. Try moving one of the cables to a different location within the pack. If the problem moves too, you have found your issue.
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Unread 05-14-2015, 06:42 PM   #8
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Default Re: Battery terminals over heating

When you post use the advanced feature, there you can upload attachments. Sounds like you cleaned up everything good but when you added the jam-nut as Sergio said that cable needs to make as much surface contact to the lead as possible. Actually melting the post is showing a resistance and causing excessive heat from that weak spot, high current there melting the post. That combo uses a 700 amp controller, in the first place I'd use 2 gauge wires not 4 but without the best possible connection to the lead surface possible even that is useless.
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