EZGO melted terminal on new battery

[ColeRacing10]

I recently replaced all 6 batteries in my EZGO electric golf cart. After running the cart for about 15 minutes, I noticed a burning smell. One of the terminals on a battery had completely melted. The battery that had this issue was in the middle of the 6-battery sequence, so I'm planning to replace all of the battery cables (in addition to the battery). What gauge cable is recommended for use on an EZGO?

[HiTechRedNeck]

Most likely cause of melted terminal is loose nut.
Bad cables/ends /corrosion can also cause this.
The batt with melted cable may be salvageable.
Several options available for repairing melted terminals.
JohnnieB seems to be the GOTO guy for batts, He may chime in soon.
If not several others have solved this problem.(i have too but will defer to others on this one.)

[Volt_Ampere]

If there is a hole in the case, you need to seal it up. You may be able to drill and tap to attach to the damaged terminal. The failure was caused by a bad connection to the terminal that melted. You need to have very clean connections and cables and ends that are in very good condition. If they are old, replace them with new (larger ones)

[Sir Nuke]

Cole.....as far as the size of the cables.....first, how old are your cables? and are they "Stock" cables? AND if your cart stock? well assuming your cart is stock and its cables are the originals, they were 6 ga. if you are going to replace the cables, up them to at least 4 ga. AND when you do, you need to replace them ALL....not just the battery cables, but ALL of the high current cables on the cart. you can get them in a complete set. check out these, they are the best ones you will find and will last you many years,

http://www.cartsunlimited.net/Batter..._Upgrades.html

[cgtech]

Melted terminals are always caused by a poor connection at the terminal (loose nut, or damaged terminal), or a cable end with high resistance at that terminal. Time for New cables, the battery supplier will probably not wanna warranty that battery.

[scottyb]

I had it happen once, my distributor had a guy who put a new post on the battery. Good as new. Call and ask.

[JohnnieB]

As mentioned, 4Ga cables minimum and all high current cables ought to be same size.
Tall tires and aftermarket motors increase the amperage drawn, so size accordingly.

If you hit a brick wall with the battery vendor, which may be likely, the melted terminal might be repairable: http://www.buggiesgonewild.com/batte...nal-repair.php

Tightening the nuts on GC battery terminals is a bit tricky. They have to be tight enough for a good electrical connection, but not tightened so much the studs turn in the soft lead they are embedded in. Proper torque is about 9 ft/lb.

[kgsc]

Look familiar? This happened to me yesterday..

[Volt_Ampere]

kgsc, that is repairable! You caught it before it melted a hole in the case.

[JohnnieB]

Originally Posted by kgsc

Look familiar? This happened to me yesterday..

Overtightened????