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Old 06-19-2017, 10:20 AM   #1
im4rmk
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Default battery cables - which ones and how to tighten

I have a 2002 club car IQ and I have had two battery terminal melts. Everything I read says my connections are either too tight or too loose, but I can't find anything telling me how tight they should be. I would also love to know why there is such a huge range of prices with cables? I use my cart about half of the year just to drive around my property. What cables should I buy? I appreciate any advice. Thank you!
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Old 06-19-2017, 10:31 AM   #2
NoleFan4Ever
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Default Re: battery cables - which ones and how to tighten

Too tight will not melt them unless the lug was cracked/broken and the current caused it. Loose will definitely melt them due to heat build up and high current usage.

You should have a high quality set of #2 or #4 (AWG/gauge) cables (I prefer 2 awg/gauge) on there with pure copper lugs and sealed heat shinked ends. They are available from several of our site sponsors here on BGW. Just click the Site Sponsors link above to get there. I know Carts Unlimited (scottyb) and I ~think Revolution Golf Carts (David Hicks) has them.

And quality is what drives the costs. Cheap stranded cable with thin ends and no seals are cheap, 600v Excelene Welding Cable w/bare copper HD lugs and 3-1 sealed heat shrink tubing is a whole lot more and will last as long as you do...
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Old 06-19-2017, 10:43 AM   #3
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Default Re: battery cables - which ones and how to tighten

The correct "dry torque" (no anti-seize) specification is 100 in-lb or about 8.5 ft-lb.

Make sure there is nothing (washer or other ring terminals) between the cable lug and the lead post of the battery.

I like the closed-end heavy walled tinned copper lugs for better corrosion protection.
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Old 06-19-2017, 11:02 AM   #4
im4rmk
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Default Re: battery cables - which ones and how to tighten

Thank you for your suggestions!
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Old 06-19-2017, 08:26 PM   #5
theboss20
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Smile Re: battery cables - which ones and how to tighten

Just to make sure everybody understands what Sergio said...no washers...no lock washers...no star washers. Be sure when you install the cable that the large battery cable is the first thing on the battery post and then if there are others smaller wires...they come next...and be sure to space them out so there is no interference from the wires when you tighten the nut. Also the nut used is also unique to golf cart batteries and is physically larger than normal to spread out the contact to the cable lugs.😎
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Old 06-20-2017, 08:45 AM   #6
Swan
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Default Re: battery cables - which ones and how to tighten

Quote:
Originally Posted by NoleFan4Ever View Post
Too tight will not melt them unless the lug was cracked/broken and the current caused it.
To tight is a problem , basically the stud is a hex bolt modeled in lead . over tightening can cause the bolt to turn within the lead . looking fine on the outside but damaged on the inside
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Old 06-20-2017, 10:11 AM   #7
Sergio
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Default Re: battery cables - which ones and how to tighten

To further clarify, the stud on a battery is not designed to carry current, all of the current is transferred from the lead post surface to the cable lug.

As long as the battery connection can get torqued, the post being loose may not be an issue, check out this press release from US Battery:
http://usbattery.com/u-s-battery-man...ery-terminals/
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Old 06-20-2017, 10:24 AM   #8
NoleFan4Ever
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Default Re: battery cables - which ones and how to tighten

Quote:
Originally Posted by Swan View Post
To tight is a problem , basically the stud is a hex bolt modeled in lead . over tightening can cause the bolt to turn within the lead . looking fine on the outside but damaged on the inside
Completely agree with that statement. But I call that a failure and the melt down would not (or should not) occur at the lug, but inside the battery where the looseness is allowing the heat to build from the current draw. The heat should be generated wherever the energy is being released or jumping across so unless he had a broken lug or something else at that contact point damaged, the terminal ends should not be melting.
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Old 06-20-2017, 01:04 PM   #9
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Default Re: battery cables - which ones and how to tighten

Quote:
Originally Posted by Sergio View Post
To further clarify, the stud on a battery is not designed to carry current, all of the current is transferred from the lead post surface to the cable lug.

As long as the battery connection can get torqued, the post being loose may not be an issue, check out this press release from US Battery:
I wonder if they had to pay royalties to Swageloc for that principle....
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Old 06-21-2017, 04:37 PM   #10
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Default Re: battery cables - which ones and how to tighten

Another old school trick. If you're using a socket wrench grab it by the head only and tighten the nut down. That's about 10 foot pounds.

Half way up the handle 25-30 foot pounds. End of the handle, well that now depends on your coat size, not your hat size.
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