Battery wire and terminal melted

[cardwellmarty]

Replaced all battery terminal wires a month ago, have had no trouble, wire and terminals melting. Cart still works.

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[Bajrang]

I've seen this a few times on community carts, and each time I've found other cables in the pack that needed tightening up. I believe that when they are not cinched down that they melt. There was an old man up here that would drill out the lugs and put a bolt (upside down) in the hole then fill the remainder with lead. When I expressed concern about a flame that close to the batteries, he said "been doin' it for forty years. Next time I brought a battery over he told me he didn't do them anymore, "had one blow up right in my face."

[cardwellmarty]

Originally Posted by Bajrang

I've seen this a few times on community carts, and each time I've found other cables in the pack that needed tightening up. I believe that when they are not cinched down that they melt. There was an old man up here that would drill out the lugs and put a bolt (upside down) in the hole then fill the remainder with lead. When I expressed concern about a flame that close to the batteries, he said "been doin' it for forty years. Next time I brought a battery over he told me he didn't do them anymore, "had one blow up right in my face."

I definitely want be doing a battery repair, can understand the safety factor, after reading other post in the forum I see that it is due to loose connections. I went out and shook threaded terminal post on battery with less damage and it is loose in battery, could be due to heat of other battery and terminal wire melting. When I replaced wires a month ago all terminal nuts were tight, but I didn't check the studs itself going into battery. This is only our second cart and am learning a lot, I will check terminals monthly when I water batteries.



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[Golferdave]

Looks like the wire was getting hot melting the insulation. (both cable ends look bad)
Cut the shrink off the lug & see what type of wire it is & how well the crimp was done

Is it an Automotive battery cable? They're not made for continuous high amp use on a golf cart.

One possible cause:
Wrong type of wire &/or wire size too small

Some other possible causes:

Loose or bad crimp
Acid migrates into the crimp & corrodes the connection
Loose/ dirty lug connection to post


At first it heats up a bit expands, stretches the bolt & nut, &/or crimp
loosening the connection more & more as it heats & cools
causing it to get hotter & hotter.
Eventually leading to failure

Yea
cart runs
but every time you press "go" it is heating the connection,

"I will check terminals monthly when I water batteries."

[cardwellmarty]

Originally Posted by Golferdave

Looks like the wire was getting hot melting the insulation. (both cable ends look bad)
Cut the shrink off the lug & see what type of wire it is & how well the crimp was done

Is it an Automotive battery cable? They're not made for continuous high amp use on a golf cart.

One possible cause:
Wrong type of wire &/or wire size too small

Some other possible causes:

Loose or bad crimp
Acid migrates into the crimp & corrodes the connection
Loose/ dirty lug connection to post


At first it heats up a bit expands, stretches the bolt & nut, &/or crimp
loosening the connection more & more as it heats & cools
causing it to get hotter & hotter.
Eventually leading to failure

Yea
cart runs
but every time you press "go" it is heating the connection,

"I will check terminals monthly when I water batteries."[emoji106]

Bought new cables a little over a month ago from Golf Cart King they are 6 gauge cables. Don't want to ask to many questions at once but could it have been loose stud mounted in terminal? Do you think 6 gauge is large enough, it was advertised for Ezgo Txt?

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[cardwellmarty]

Originally Posted by cardwellmarty

Bought new cables a little over a month ago from Golf Cart King they are 6 gauge cables. Don't want to ask to many questions at once but could it have been loose stud mounted in terminal? Do you think 6 gauge is large enough, it was advertised for Ezgo Txt?

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I know as of now its a guess because damage is already done , but all possible sceneries will help me to what to keep an eye on.

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[cardwellmarty]

Originally Posted by cardwellmarty

I know as of now its a guess because damage is already done , but all possible sceneries will help me to what to keep an eye on.

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Ends of cable are tight, even after all the heat.

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[Seaquell]

6 gauge is stock and is the bare minmum for golf if you are hard on the cart you need at least 4 gauge or even 2 if your going to modify it, thats what I use.

Were you under a heavy strain when you melted the terminal and wire?

[Seaquell]

That battery that melted has top posts on it I've never seen that on a golf cart battery.
The batt also says super start, is it a golf cart battery or a 6v tractor starting battery?
That may be your problem?

[cardwellmarty]

Originally Posted by Seaquell

6 gauge is stock and is the bare minmum for golf if you are hard on the cart you need at least 4 gauge or even 2 if your going to modify it, thats what I use.

Were you under a heavy strain when you melted the terminal and wire?

It's a stock cart, I live in Alabama so we have hills, we don't off road with it though. I was going up a long drive ( hill) the cart was under a load, carts weight, plus two people weighing 250 lbs total. I smelt rubber burning and checked it.

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