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Electric Yamaha Electric Yamaha Golf Cars; G1 through "The Drive" and U-Max Utility Vehicles |
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09-11-2021, 01:29 PM | #1 |
Not Yet Wild
Join Date: Dec 2015
Location: NY
Posts: 11
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G9 cart keeps melting battery terminals
We have a Yamaha G9 golf cart, stock other than 4 gauge cables and a plastic bed on the back with Trojan T105 batteries.
It keeps melting the terminals off of the batteries. Thought it was due to it being used to tow a leaf sweeper around the yard, so that practice was stopped, but the kids had it out back today and it melted another terminal: IMG_20210911_121418406_HDR.jpg Electrolyte levels are ok through the pack, all terminals are tight (even the one that melted off), but it keeps frying terminals. Any ideas why this might be happening? Also, which controller does this have? This is the controller: IMG_20210911_121351432_HDR.jpg Is this a resistance type controller? Thanks Aaron Z |
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09-11-2021, 01:36 PM | #2 |
Gone Wild
Join Date: May 2012
Location: Rio Verde, Az
Posts: 7,126
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Re: G9 cart keeps melting battery terminals
This is always caused by a poor connection between the cable and the battery terminal. Replace the cable ends and batteries that are damaged and make sure that they are very clean when you reattach them.
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09-11-2021, 05:48 PM | #3 | |
Not Yet Wild
Join Date: Dec 2015
Location: NY
Posts: 11
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Re: G9 cart keeps melting battery terminals
Quote:
IMG_20210911_162609302_HDR.jpg We will see how that works. Aaron Z |
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09-11-2021, 05:50 PM | #4 |
Gone Wild
Join Date: May 2012
Location: Rio Verde, Az
Posts: 7,126
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Re: G9 cart keeps melting battery terminals
I see some problems. Always put the high power cable on the terminal first and the low current cable on top. You have some the other way. I see that done wrong often.
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09-11-2021, 09:12 PM | #5 |
Not Yet Wild
Join Date: Dec 2015
Location: NY
Posts: 11
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Re: G9 cart keeps melting battery terminals
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09-11-2021, 11:25 PM | #6 |
Gone Wild
Join Date: May 2012
Location: Rio Verde, Az
Posts: 7,126
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Re: G9 cart keeps melting battery terminals
Hope your problems are solved!
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09-12-2021, 12:59 AM | #7 |
Gone Wild
Join Date: Nov 2016
Location: near Calgary, AB, Canada
Posts: 1,511
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Re: G9 cart keeps melting battery terminals
Over-torqued battery studs can also result in melted terminals.
If a stainless steel stud is significantly over-torqued, the stud can separate or loosen from the lead post that the stud is seated in. This loosening or separation will result in increased resistance between the stainless stud and the lead post or a reduced contact force between the battery cable lug and the lead post. Either of these can increased the resistance in the circuit resulting in additional heat being generated at higher amperages, which can melt the lead post in the battery. The torque specification for these battery studs is 100 INCH-POUNDS, which is ONLY 8.3 FOOT-POUNDS! If battery studs have been over-torqued significantly any time in the past (lets says by a previous owner perhaps), then that can haunt you later in the batteries life resulting in a melted post. There are many instances of melted posts noted in the BGW forum ... as well as recommended repair procedures that can be searched out. |
09-12-2021, 07:42 AM | #8 | |
Not Yet Wild
Join Date: Dec 2015
Location: NY
Posts: 11
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Re: G9 cart keeps melting battery terminals
Quote:
https://www.buggiesgonewild.com/batt...nal-repair.php https://www.buggiesgonewild.com/showthread.php?t=81220 Just silicone to seal the melted hole, or would JB Weld (or some other epoxy) be better? Aaron Z |
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