Excessive Corrosion

[golf cart man]

Ive had around 15 carts in my life and this 2000 club car DS is by far the worst with battery corrosion. I am not sure what is causing it or what to do. The batteries are 2013 trojans. The cart is 48 volt used everyday for golf and charged after each round. Batteries are not overfilled or boiling over when charging either. I have tried terminal cleaner, terminal protectant(the red spray), I've replaced the cables. Still comes back a week or so later after cleaning. Any ideas?? Never had this issue before on any of my carts.

[Golferdave]

Bad seal on battery tops

Doesn't happen when you have it ?

at home, different charger, voltage, run down till almost dead ...something

Pictures?

[mrgolf]

Are you saying just on the battery tops?

[Muddog]

Check each battery voltage 24 hours after charge, a bad battery can cause overcharging on the rest of the pack and cause excessive gassing.
Never thought about bad seals under caps, but it's possible. Flip the rubber seals under the caps.
Your caps may not be seated all the way. Hit each end of the caps with the heel of your hand to be sure they are seated.

[golf cart man]

ok, i will check the tops. I cleaned them again today so I will get pictures next time if needed. Occurs all around the bolts on a few of the batteries not every single terminal. However checked to make sure all terminal nuts are on to proper torque and they are good.

[Golferdave]

I've seen leaks around the case & posts too

Also ckeck the cell caps are clean, soak in water/baking soda solution
Rinse well
If plugged, it pressures the case & forces electrolyte out around the posts

[LakeNut]

I tend to agree, if it is a fairly new behavior on this cart, measure the voltage on each battery. I'm thinking you have a cell or two shorted out, causing all the others to overcharge, bubble, and splatter a little acid out.

[golf cart man]

Ok, I will also load test each. Thanks for the suggestions everyone

[theboss20]

I agree...one bad battery in a series system will throw off the charger for sure...another way to determine the bad battery or batteries is to pull all the battery caps and plug in the charger...the bad battery will either not bubble in the cells or bubble before all the other batteries.

[Muddog]

Originally Posted by golf cart man

Ok, I will also load test each. Thanks for the suggestions everyone

Good thread, I learned 2 things from it. Thanks for the knowledge.
Let us know how load test goes.