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Electric EZGO Electric EZ GO Marathon, Medalist, TXT and RXV.



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Old 03-26-2021, 12:12 PM   #1
LeeFeed
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Default oh oh

We noticed one of our battery cable was frayed, but the cart was working. We decided to change out the old cables, with a new super duty. When we were finished, we checked the lights and they worked but when we applied the accelerator the battery with the replaced cable sparked and popped. But the lights worked on the cart. No power to the cart to make it move, only the popping. Anyone have a suggestion? Could it be a bad battery, it is 5 years old or do you think it was the new cable. We followed the routine and have changed cables in the past but this has never happened. Again, the cart was working before we messed with it but I am sure it would go again. This is EZGO TXT 2002 and it is our yard cart. We use it a couple days a week for short rides to our mailbox down the mountain and run between our home and barn hauling brush occasionally.
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Old 03-26-2021, 12:32 PM   #2
kgsc
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Default Re: oh oh

Lights are probably pulling power from the back 2 batteries on the passenger side so not really a test. What cable did you replace? And is it possible it is touching something it isn’t supposed to?
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Old 03-26-2021, 12:38 PM   #3
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We replaced the long cable that runs from front left to rear left. Again it was running but the cable was fraying and I knew it would go. There was quite a bit of corrosion but there was water because I checked all the batteries last week. It will pop and there is a tuft of smoke.
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Old 03-26-2021, 12:45 PM   #4
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Default Re: oh oh

Might be the nut on the battery stud got over tightened and twisted the stud in the soft lead battery terminal. (Torque spec is only 95 - 105 lb/in - which translates to 7.9 -8.75 ft/lb)

The stud is a stainless steel hex head bolt embedded in the lead battery post. If too much torque is applied to the nut holding the cable down, the hex head turns in the lead and only the six points make contact, so the current density skyrockets and you get spitzensparken mit poppencorken when you try to draw enough amps to move cart.

Could also be the new cable is bad.
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Old 03-26-2021, 12:50 PM   #5
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So this is a battery to battery jumper from the front to back battery on the driver’s side. That is pretty straightforward but if you are getting sparks there something is loose.
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Old 03-26-2021, 12:55 PM   #6
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Default Re: oh oh

Another thing to check is that when you removed the old cable, If it was one of the hollow cable ends instead of the solid terminal ends...is that the old cable did not separate and left part of it on the battery terminal which is sparking...it will not allow the nut to tighten all the way which will cause spark if there is any gap between nut/wire/terminal when accelerator is applied.
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Old 03-26-2021, 12:57 PM   #7
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Could it be a bad battery post because it might have been tightened too much. Replace the battery?
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Old 03-26-2021, 01:00 PM   #8
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A side note: The terminal that is getting a lot of corrosion is the one in the rear drivers side Positive terminal is due to that being where water drips down from the body right above it where the seat rest...A design flaw in my opinion but I would apply heavy coat of terminal protection spray on that particular terminal to prevent this down the line...
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Old 03-26-2021, 01:03 PM   #9
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Yes that is the terminal that had the fray near the connection. Do you think it might be a bad battery? I could get all new cables and replace the one battery. Do you think that might solve the problem in the future?
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Old 03-26-2021, 01:07 PM   #10
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I'll be honest but its not what your gunna wanna hear...If all of yours batteries are at that 5 year old mark I would just go ahead and replace the set, otherwise you are going down a huge rabbit-hole of replacing one battery at a time from now until eternity...expensive solution but your only truly headache-proof one...
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