Help 1984 CC melted cable

Nodrog

Was doing some routine maint. on my cart when I discovered this, not sure why it happened cart still runs, and everything. Any suggestions?

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BGW

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Allmanac

Looks like that cable had a lot of resistance causing it to melt. Are all connections tight and corrosion free? You will need to replace that cable but you might as well get a new set. While your at it upgrade to 4awg welding cables which will help with less resistance. That battery terminal looks like it's been chewed on. Even if there is no visible corrosion there may be some inside the insulation back from the terminal rings which will cause resistance and heat.

Nodrog

The battery post actually is raised up from the battery and has a lot of stuff built up under it, which maybe the heat and resistance caused? I was just worried there was another major issue replacing cables won't be a big issue for me. Not sure but may have to replace the battery to.

Allmanac

That battery post lifting from the battery could be a bigger problem waiting to happen. I'm not an expert by no means but some of the experts here may chime in and give you further advice. How old is your pack? Would recommend changing the pack as a whole but if that is not in the budget try to find a used battery of about the same age and voltage when fully charged. If you drop in a new battery your pack will not be balanced and you will quickly degrade the new battery.

Nodrog

Batteries were all put in January 2017, and they all to include the troubled one show 6.37 to 6.40 volts sitting.

Allmanac

Well all your batteries are at 100% SOC so they are in pretty good shape voltage wise. Less that rough looking pos post in your picture. Well one things for sure you need new cables. Do you have a picture of the whole battery compartment so we can see the condition of the other cables? Maybe one of the experts will advise on the battery in question. I would hate for you to replace cables just to have the same thing happen again.

Budule

looks like the cable is just laying on top of the post while also attached to the stud ….if that's the way it was running , you were kinda welding it ….probably took a while to rub through the insulation though....

Budule

clean it all up ,if the stud is not loose inside the battery its probably ok...load test if you can reroute new cable ….

Fairtax4me

More than likely the connection of the cable to the crimp was bad or got some corrosion in it.

I wouldn’t try to re-use that stud. Drill into the post next to it and tap for a 5/16-18 thread stud. Only need to drill in about 1/2”. Any deeper and you may drill all the way through it.
Thread the stud into the post and use a new nut. Don’t overtighten the nut. About 90-100 in-lbs is what most battery manufacturers specify. Use a lock washer to keep it from loosening.

Nodrog

Exactly what I think happened to, I did buy a new cable and battery and reroute the cable. The battery post was fried the nut and stud both just turned and so had no choice but to replace the battery. All good now I think.