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Old 05-20-2010, 06:36 PM   #1
ray6059
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Default Brand new battery melted a terminal?

Any ideas what would cause this problem? My TXT 36V 04 one of the terminals is just melted on one battery the batteries are only 3 weeks old.
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Old 05-20-2010, 06:48 PM   #2
scottyb
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Default Re: Brand new battery melted a terminal?

I have seen this happen.... it is due to a loose or bad connection...

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Old 05-20-2010, 08:26 PM   #3
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Default Re: Brand new battery melted a terminal?

Loose or bad connection. (cant take it back for a warrantee either) Connections need to be checked at least once a month and sooner on new batteries. They WILL get loose.

Heres a way to repair the terminal. Battery terminal repair
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Old 05-20-2010, 08:54 PM   #4
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Default Re: Brand new battery melted a terminal?

Funny story here ........
I sold a set of batteries to the head of the cart barn at a local golf course for his personal cart. He had his barn tech install them ..... 3 weeks later he called me and said bring a new battery one of his 'blew up'
The battery looked like it had blown up the post had melted off and fell onto the case melting a big hole down into it....

Nice big 2 ga cables his tech had made had 3/8 not 5/16 holes in them and no lock washers..... so they got loose fast.... you should have seen the shock on his face when I load tested a good battery with no terminal OH sorry....
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Old 02-14-2012, 07:31 AM   #5
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Default Re: Brand new battery melted a terminal?

Quote:
Originally Posted by roady89 View Post
Loose or bad connection. (cant take it back for a warrantee either) Connections need to be checked at least once a month and sooner on new batteries. They WILL get loose.
.....
Is this advice for normal cart use or for carts used in extreme situations?

Someone I know has had the terminals melt on two different batteries (one was a replacement for the other).
The cart is just used within a residential community on paved roads, so it would seem vibration that would loosen the connections would be minimal. Of course, it's not a bad idea to check the connections once a month, but I'm wondering if the owners will actually DO this.

Thanks for any help.
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Old 02-14-2012, 08:26 AM   #6
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Post Re: Brand new battery melted a terminal?

Thanks Roady and Scotty, we received brand new 8v Trojans ~ 4 months ago and one of the posts was completely sheared when delivered. Usual blame was apportioned between courier and despatcher etc........... I cast a new "post" with lead but have noticed that there is blue/green deposits devoloping where the join is. Pretty hard to do this without risking safety by raising the temp of the host connection (on the battery itself). Will easily do the method as suggested by you clever guys. (have all the gear)
Scotty, will PM you re cables for my CC 03 DS.
Donation made to the site for invaluable info. Keep it going...........
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Old 02-14-2012, 08:37 AM   #7
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Default Re: Brand new battery melted a terminal?

Quote:
Originally Posted by KarrathaSteve View Post
Thanks Roady and Scotty, we received brand new 8v Trojans ~ 4 months ago and one of the posts was completely sheared when delivered. Usual blame was apportioned between courier and despatcher etc........... I cast a new "post" with lead but have noticed that there is blue/green deposits devoloping where the join is. Pretty hard to do this without risking safety by raising the temp of the host connection (on the battery itself). Will easily do the method as suggested by you clever guys. (have all the gear)
Scotty, will PM you re cables for my CC 03 DS.
Donation made to the site for invaluable info. Keep it going...........
I was going to suggest sealing the joint with a solder gun and solder but your probably would be better off using the repair method above. My experience casting lead is that it shrinks a tad as it cools and normally does not adhere well to the surfaces it touches. I am surprised that you are getting a decent contact with the cast part. I'll bet you can wiggle it with you hand and pull it off if you tried.
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Old 02-14-2012, 08:50 AM   #8
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Default Re: Brand new battery melted a terminal?

It is hazardous to repair a battery terminal. Very explosive hydrogen gas is present in the case when the battery is charged. There are methods to do this I won't suggest any of them because it just isn't something I'm that comfortable with.
I have the carbon molds and have had some success pouring a new lead post using a torch but! My experimental repaired post also developed a bad seal, (dreaded green stuff) leading to failure.
Call your local battery shop and ask them if they do post repairs. Mine did them for me for about $15 each.

I don't think post replacement is something the average guy safely do.
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Old 02-14-2012, 08:50 AM   #9
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Default Re: Brand new battery melted a terminal?

Good Info Battery repair
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Old 02-14-2012, 09:41 AM   #10
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Default Re: Brand new battery melted a terminal?

Be extremely careful with any kind of heat around a battery! If doing the terminal repair, remove that battery and take it outside to work on it. Even the commutator sparks in an electric drill can cause the hydrogen gas to explode. I usually put a fan to circulate air when I do any work on my batteries. I've had batteries explode before, and it's no fun! Neither is the cleanup afterwards!
Never try to melt lead back onto a damaged battery terminal, unless you're a shop with the proper equipment to do this!!! It is really dangerous!

This was taken in part from Wikipedia: Hydrogen gas forms explosive mixtures with air if it is 4–74% concentrated and with chlorine if it is 5–95% concentrated. The mixtures spontaneously explode by spark, heat or sunlight. The hydrogen autoignition temperature, the temperature of spontaneous ignition in air, is 500 °C (932 °F).[13] Pure hydrogen-oxygen flames emit ultraviolet light and are nearly invisible to the naked eye.
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