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Unread 05-14-2009, 07:44 AM   #1
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Default Another melted battery terminal discussion

New (to us) 2001 EZGO.

I'll be doing the terminal repair posted here -http://www.buggiesgonewild.com/battery-terminal-repair.php

.. however, if you take a look at the pic of the +ve lead (still on the stud that came out of the terminal!) it looks like it had been previously repaired - the black tape around the end sort of gives it away.

Do you think that was the cause of the heat (connection was tight) OR was it having the smaller connectors underneath the main battery lead?

Just fishing for opinions. I think the main power lead should be first, with accessories on top (possibly even above the nut with a second nut holding them in place?)

Included the melted terminal for your viewing pleasure.. :)
..a
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Unread 05-14-2009, 08:01 AM   #2
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Default Re: Another melted battery terminal discussion

I shouldn't make any difference what order you stack them in as long as they are clean and tight
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Unread 05-14-2009, 08:43 AM   #3
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Default Re: Another melted battery terminal discussion

I always put the battery cable on first and then my asseccories. I even put a small washer between the terminals. I do not know if this helps/hurts the operation of the unit.

Whne I see carts do this I always repair (If I can) the battery terminal and replace the cable, just to make sure the cable is not the problem.
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Unread 05-14-2009, 09:23 AM   #4
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Default Re: Another melted battery terminal discussion

Washers are good for mechanical connections, but they just introduce another layer for corrosion in our sparky carts. Replace that cable, repair the other 2 wires, make sure everything is CLEAN/BRIGHT/TIGHT, and protect with terminal dressing.
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Unread 05-14-2009, 10:03 AM   #5
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Default Re: Another melted battery terminal discussion

I can't seem to find an easy way to get the speed control out or open, which is where the other end of the red cable is attached (internally)..
..a
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Unread 05-14-2009, 03:44 PM   #6
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Default Re: Another melted battery terminal discussion

Figured that out. Another trip to WalMart and I now have new cables and all sorts of other stuff to get it working right.

So much for "new" batteries, according to the seller. Found an 3/07 sticker on one of them..
..a
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Unread 05-14-2009, 06:08 PM   #7
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Default Re: Another melted battery terminal discussion

Are you using Walmart automotive battery cables on your electric cart? The flimsy lugs on those will melt down. They can't take the sustained amp draw of a cart.
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Unread 05-14-2009, 08:05 PM   #8
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Default Re: Another melted battery terminal discussion

I am making my own cables from 4ga copper stranded cable and copper lugs, which will be crimped then soldered, and treated with corrosion-preventative..
..a
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Unread 05-14-2009, 08:12 PM   #9
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Default Re: Another melted battery terminal discussion

Quote:
Originally Posted by eflyguy View Post
I am making my own cables from 4ga copper stranded cable and copper lugs, which will be crimped then soldered, and treated with corrosion-preventative..
..a
Excellent. You fast learner! You try wheelie now!
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Unread 05-14-2009, 08:37 PM   #10
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Default Re: Another melted battery terminal discussion

From my experience,(golf course operator) ALL of our meltdowns are caused by a loose, bad, dirty, partially burnt, bad cable or corrodid connections. It is very critical to keep ALL the connections on an electric cart clean.
Many of the problems caused are not visible until it is too late. It is usually oxidation between the lead battery part of the terminal and the battery cable end, where they touch.
This "good" looking connection will draw heat, create stress on the metals and will be borderline on meltdown long before it happens.
It is really better to remove and clean all your cables on a regular basis.
The acid needs to be removed from all parts frequently. The acid will get bounced out of your batteries. It also produces fumes during charging that will condense as it leaves the batteries, leaving a film.
Also, the 1st thing that will kill your batteries is your tire pressure. Low tires KILL batteries fast.
That may not be the right order, but you get the idea.
The second thing is overfilling batteries. When the batteries are charging they heat/ boil, as the fluid expands it overflows onto the floor. When you then fill it, youre diluting the electrolite weakening the battery. Keep it within the lines. above the plates and about 1" from the top. (your manuf. recommended levels)
I know most of this is known to many out there, and some of my theories may not be correct. This is based on 12 years replacing/ repairing these basttaries, and hope some it is informative and helpful to somebody out there.
Happy trails........

Last edited by tonyton; 05-14-2009 at 08:40 PM.. Reason: levels
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