lifted club cars - lifted ezgo
Home FAQDonate Who's Online
Go Back   Buggies Gone Wild Golf Cart Forum > Golf Cart Repair and Troubleshooting > Electric Yamaha
Electric Yamaha Electric Yamaha Golf Cars; G1 through "The Drive" and U-Max Utility Vehicles



Post New Thread  Reply
 
Thread Tools Display Modes
Old 09-11-2021, 01:29 PM   #1
aczlan
Not Yet Wild
 
Join Date: Dec 2015
Location: NY
Posts: 11
Default 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
aczlan is offline   Reply With Quote
Alt Today
BGW

Golf car forum Sponsored Links

__________________
This advertising will not be shown in this way to registered members.
Register your free account today and become a member on Buggies Gone Wild Golf Cart Forum
   
Old 09-11-2021, 01:36 PM   #2
Volt_Ampere
Gone Wild
Yamaha
 
Join Date: May 2012
Location: Rio Verde, Az
Posts: 7,126
Default 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.
Volt_Ampere is offline   Reply With Quote
Old 09-11-2021, 05:48 PM   #3
aczlan
Not Yet Wild
 
Join Date: Dec 2015
Location: NY
Posts: 11
Default Re: G9 cart keeps melting battery terminals

Quote:
Originally Posted by Volt_Ampere View Post
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.
They are clean, I replaced all the wires (because I had some on the shelf) and the connections all got some vaseline to help keep the corrosion at bay.
IMG_20210911_162609302_HDR.jpg

We will see how that works.

Aaron Z
aczlan is offline   Reply With Quote
Old 09-11-2021, 05:50 PM   #4
Volt_Ampere
Gone Wild
Yamaha
 
Join Date: May 2012
Location: Rio Verde, Az
Posts: 7,126
Default 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.
Volt_Ampere is offline   Reply With Quote
Old 09-11-2021, 09:12 PM   #5
aczlan
Not Yet Wild
 
Join Date: Dec 2015
Location: NY
Posts: 11
Default Re: G9 cart keeps melting battery terminals

Quote:
Originally Posted by Volt_Ampere View Post
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.
Thanks, they are all fixed now.

Aaron Z
aczlan is offline   Reply With Quote
Old 09-11-2021, 11:25 PM   #6
Volt_Ampere
Gone Wild
Yamaha
 
Join Date: May 2012
Location: Rio Verde, Az
Posts: 7,126
Default Re: G9 cart keeps melting battery terminals

Hope your problems are solved!
Volt_Ampere is offline   Reply With Quote
Old 09-12-2021, 12:59 AM   #7
ThreeCW
Gone Wild
 
ThreeCW's Avatar
Cushman
 
Join Date: Nov 2016
Location: near Calgary, AB, Canada
Posts: 1,511
Default 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.
ThreeCW is offline   Reply With Quote
Old 09-12-2021, 07:42 AM   #8
aczlan
Not Yet Wild
 
Join Date: Dec 2015
Location: NY
Posts: 11
Default Re: G9 cart keeps melting battery terminals

Quote:
Originally Posted by ThreeCW View Post
There are many instances of melted posts noted in the BGW forum ... as well as recommended repair procedures that can be searched out.
Found a couple, have done that in the past on this cart, hasn't always seemed to last though.
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
aczlan is offline   Reply With Quote
Reply
Go Back   Buggies Gone Wild Golf Cart Forum > Golf Cart Repair and Troubleshooting > Electric Yamaha


Thread Tools
Display Modes


Similar Threads
Thread Forum
Trojan Ranger 160 battery terminals overheating and melting battery plastic Electric Club Car
99 TXT Battery terminals keep melting Electric EZGO
battery terminals melting Electric EZGO
battery melting Electric Club Car
Battery terminals melting Electric EZGO


All times are GMT -5. The time now is 10:55 AM.


Club Car Electric | EZGO Electric | Lifted Golf Carts | Gas EZGO | Used Golf Carts and Parts

Powered by vBulletin® Version 3.8.9
Copyright ©2000 - 2024, vBulletin Solutions, Inc.
This Website and forum is the property of Buggiesgonewild.com. No material may be taken or duplicated in part or full without prior written consent of the owners of buggiesgonewild.com. © 2006-2017 Buggiesgonewild.com. All rights reserved.