EZGO PDS melted battery post - out of luck

[Mancebo]

So as some of you know, I replaced my dcx controller with the xct. Had a few hiccups, but after a replacement all was well. Fast forward, I'm testing the cart, probably third longest stint since swap, and I smell it. The scary smell when driving an electric cart. That said, soc meter goes out and cart is dead. Lift seat, and sure enough battery post melted, #4 battery.

So not happy, from my research I may have over tightened the post after all the on and off. Anything else I should look for that may cause melted post?

[R.Boyd]

Make sure the cable doesn't have a bad connection inside the terminal were it crimps. My uncle burnt up the post on about 5 or 6 different batteries before I showed him what the problem was. There was a bad connection somewhere there.

[cgtech]

If your cables are the cheap auto parts store cables with the strands running up to the end like these, get rid of them.

[ThreeCW]

Bad connections add resistance and generate heat.

Read up on what Trojan has to say in this attachment.

[rib33024]

You might be able to save the battery


http://www.buggiesgonewild.com/batte...nal-repair.php

[Mancebo]

Thanks everyone! Having "Justified" the new controller, and of course FN2 with the CEO, now I have to "discuss" a new battery pack.

I have removed the battery nuts a few times and have always tightened them up. But with this last project, with the back and off/back and off I may have torqued on them to much.

I been looking on a lot of post and will either get a torque wrench for the new batteries, or as JohnnieB recommends hand tight them with a socket on a handle vs ratchet.

[Cobra,1]

I always make sure terminals are tightened with torge wrench. But thinking if it melted it would be loose connection,not over tight terminal nut?
Battery cable Clean?
Can you post picture of terminal to see if it can be repaired.
May not need new pack,just 1 new battery