Why did my cable melt

[Tj4orange]

i have 91 ezgo marathon. i went to drive it and noticed the lights would not switch on. i lifted the seat and noticed the cable coming from "the little square plate that the forward reverse neutral switch is wired to, about five or six bolt post with nuts on them), and going to the battery was starting to melt . there is the o ring that is crimped to the wire. right on the back of this wire is where the cable melted. about a inch long about half to three quarters around. this particular post had two red cables and a small aux wire for light running to it. the bolt on battery post was tight and didn't look to be a noticeable corrosion on it. wish i could figure out how to post a pic. any ideas on why this happened?

[jakesnake27]

Corrosion on the inside of the cable where you can't see it caused that...

[Tj4orange]

jake, now that look closer i see what you're saying. i took pics at night with phone. this is the first i have seen them on cpu and can see. so freaking frustrating! now to order new cable... errrrr

[FLmedic]

Whats the white powder all over that battery? Baking soda to neutralize acids? Should I be doing that too?

[Revolution]

Go ahead and change them all out.

[jjance]

Everybody that works on batteries should have a 200 in/lb torque wrench. The corrosion starts with a loose connection and progresses up to a burnt cable. Check your torque setting frequently especially if you use star washers. Stainless battery studs should be torqued to 120 in/lbs.

[JohnnieB]

Originally Posted by jjance

Everybody that works on batteries should have a 200 in/lb torque wrench. The corrosion starts with a loose connection and progresses up to a burnt cable. Check your torque setting frequently especially if you use star washers. Stainless battery studs should be torqued to 120 in/lbs.

The might be a tad too much.
Nearly all cart batteries are have Embedded Low, or Embedded High, Profile Terminals (ELPT or EHPT), so the torque range is 95 to 105 lb/in.

The attached chart is from Trojan Battery, but it is the same for other brands since a stainless steel hex head bolt embedded in lead is a stainless steel hex head bolt embedded in lead no matter whose name is on the box.

[JohnnieB]

Also, Here is a chart identifying the various terminal configurations that go with the above torque specs.

[teecro]

Originally Posted by JohnnieB

The might be a tad too much.
Nearly all cart batteries are have Embedded Low, or Embedded High, Profile Terminals (ELPT or EHPT), so the torque range is 95 to 105 lb/in....

To which 105 inch pound is not even 9 foot pounds making it very easy to over torque even with a short box end wrench....

[yurtle]

Which is why many of us use a nut driver, not a wrench. It's also safer than a wrench, which can accidentally hit an adjacent terminal.

I have a friend who used a wrench and literally melted his wedding ring to his finger.