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Old 02-24-2019, 03:49 PM   #1
stevewise033
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Default Broken / Melted Battery Terminal

02 DS IQ 48V Sepex cart

Went for a ride through the neighborhood today, and the cart just shut down and quit. Upon inspection I discovered the main pack positive battery terminal basically got so hot, the lead on the terminal melted and the positive bolt came out of it. The main positive wire to/from the solenoid was very hot, but otherwise, ok. See attached pics. Any ideas what may have caused this, and is there anyway to salvage the battery ? I really hate to buy 6 new batteries because of one losing its terminal bolt. The pack is still in good shape. Thanks for any help

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Old 02-24-2019, 03:55 PM   #2
jdavila99999
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Default Re: Broken / Melted Battery Terminal

Look up this video on YouTube

I did this and it worked perfectly


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Old 02-24-2019, 04:11 PM   #3
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Default Re: Broken / Melted Battery Terminal

Thanks 99999. I'll check it out

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Old 02-24-2019, 05:08 PM   #4
Olddog72
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Default Re: Broken / Melted Battery Terminal

I fixed a couple with 5/16 2" hanger bolts,easy to do .
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Old 02-24-2019, 05:09 PM   #5
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Default Re: Broken / Melted Battery Terminal

Jdavila99999, you da man. Good video. Quick and simple repair and I'm 10-8 again. I'm just concerned about how hot the terminal got. I'll monitor the pack for awhile each time I go out

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Old 02-24-2019, 05:11 PM   #6
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Default Re: Broken / Melted Battery Terminal

Thanks Olddog72. It was an easy fix. I appreciate it

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Old 02-24-2019, 07:03 PM   #7
WalterM6
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Default Re: Broken / Melted Battery Terminal

To me it looks like the battery terminal was over-tightened. That broke the bolt loose from its lead seat which caused a bad connection with produced the heat. Only tighten the lugs to 100 in/lbs of torque max.
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Old 02-24-2019, 07:58 PM   #8
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Default Re: Broken / Melted Battery Terminal

Quote:
Originally Posted by stevewise033 View Post
Thanks 99999. I'll check it out

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[emoji1417]


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Old 02-24-2019, 08:00 PM   #9
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Default Re: Broken / Melted Battery Terminal

Quote:
Originally Posted by WalterM6 View Post
To me it looks like the battery terminal was over-tightened. That broke the bolt loose from its lead seat which caused a bad connection with produced the heat. Only tighten the lugs to 100 in/lbs of torque max.


Also if it was loose it will arc . heat up and melt.


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Old 02-24-2019, 08:14 PM   #10
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Default Re: Broken / Melted Battery Terminal

Well I try to check the water level in them every month. I may have overtightened that post. I check all the cables when I check the water. Thanks guys for the responses. That's how u learn

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