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Old 11-05-2013, 01:56 PM   #1
superuo
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Default 99 TXT Battery terminals keep melting

I am not sure what is going on. I have had three batteries now melt at the terminal until the battery cable falls away with the bolt of the battery terminal still attached.

Battery pack is 36v. cabling in question is 4 gauge. Not sure what else to add.

Cart runs fine in all other respects.

pictures attached of two of the batteries.
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File Type: jpg lees samsung 305.jpg (84.6 KB, 0 views)
File Type: jpg lees samsung 306.jpg (71.5 KB, 0 views)
File Type: jpg lees samsung 307.jpg (88.6 KB, 0 views)
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Old 11-05-2013, 01:58 PM   #2
jakesnake27
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Default Re: 99 TXT Battery terminals keep melting

Is it happening to different batteries?
Loose connections are typically the culprit for melting terminals.
Loose connections create resistance, which means heat, which means melting...
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Old 11-05-2013, 02:04 PM   #3
Wylie_Tunes
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Default Re: 99 TXT Battery terminals keep melting

If its the same cable/battery post, then do a voltage drop on that cable.
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Old 11-05-2013, 02:18 PM   #4
remac
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Default Re: 99 TXT Battery terminals keep melting

I see three different types of batteries in the picture.
US1800, Interstate 2200, and Powerfast and I don't see the whole name,
but on those two even the labels look different.

You might make a list of the batteries you have and include
Manufacturer, AmpHour Rating, and Date (usually on the NEG post).
It is better to keep your batteries as similar as possible
or a dissimilar battery can draw differently and strain the others.

Also, if you have had enough heat to melt a post, I would worry
about the cable connection and if it was damaged too.
You might need to replace the cables.
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Old 11-05-2013, 02:19 PM   #5
superuo
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Default Re: 99 TXT Battery terminals keep melting

Quote:
Originally Posted by Wylie_Tunes View Post
If its the same cable/battery post, then do a voltage drop on that cable.
Same battery, different posts. twice the negative, once the positive.

Sorry to be so dumb, but what is a voltage drop?
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Old 11-05-2013, 02:19 PM   #6
rib33024
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Default Re: 99 TXT Battery terminals keep melting

If you had cables made to handle the amp for a golf cart, this may fix the problem, those auto cables you have on your cart are not made for a golf cart, is this cart used on hills or flat ground? here repair you batteries and get some good cables and you will be go to go


http://www.buggiesgonewild.com/batte...nal-repair.php
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Old 11-05-2013, 02:28 PM   #7
Wylie_Tunes
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Default Re: 99 TXT Battery terminals keep melting

Quote:
Originally Posted by superuo View Post
Same battery, different posts. twice the negative, once the positive.

Sorry to be so dumb, but what is a voltage drop?
A voltage drop test allows you to test the condition of a cable or wire. Much more accurate then measuring the cable ohms. If the cable is corroded down in the insulation, it may not be seen with the naked eye, but can be found with voltage drop test.
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Old 11-05-2013, 02:31 PM   #8
yurtle
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Default Re: 99 TXT Battery terminals keep melting

Another possibility is if the terminals were overtightened, it could loosen the stainless steel bolt, which is embedded in very soft lead. Proper torque can be gotten from you battery manufacturer, but it's measured in inch-pounds, not foot-pounds. Nearly every fastener can be snugged until "tight", and if you aren't careful, you can easily overtighten battery terminals.
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Old 11-05-2013, 02:53 PM   #9
superuo
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Default Re: 99 TXT Battery terminals keep melting

Quote:
Originally Posted by remac View Post
I see three different types of batteries in the picture.
US1800, Interstate 2200, and Powerfast and I don't see the whole name,
but on those two even the labels look different.

You might make a list of the batteries you have and include
Manufacturer, AmpHour Rating, and Date (usually on the NEG post).
It is better to keep your batteries as similar as possible
or a dissimilar battery can draw differently and strain the others.

Also, if you have had enough heat to melt a post, I would worry
about the cable connection and if it was damaged too.
You might need to replace the cables.

Battery pack + Interstate 232AH
then Powerfast 208ah (the melted one)
then us1800 208ah
then Interstate 232ah
then us 1800 208ah
then battery pack - is powerfast 210ah

The previous two that melted were both interstate 232ah

I have forgotten to mention that the battery pack negative battery has previously exploded and by exploded I mean into many pieces and it was also an interstate. I will include a picture of that one.

so in all I have replaced 4 batteries over a 2 month period.

The cart will run fine for a week or two and then one day the terminal will be gone.
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Old 11-05-2013, 02:56 PM   #10
scottyb
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Default Re: 99 TXT Battery terminals keep melting

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