Golf Cart Battery Post Burn Out

by Ernest McConnell
(Chelsea, AL USA)

I purchased my used 2002 EZ-Go with new batteries three years ago with new (no visible name) batteries. The cart is used for neighborhood cruising 3-4 times per week in summer and less in the winter. The batteries are charged every time I use it regardless of the usage.

I have had trouble with battery post corrosion despite new cables and careful attention to water levels. However, the battery water apparently boils over (even with careful water levels just above the cell) and leaves an acid residue on the garage floor.

During a 45-60 minute ride in the evenings, the cart will stop at least once while going forward (with the back-up bell beeping), and then, once stopped, start forward again as if nothing happened.

Last evening, I was riding, the cart stopped and would not restart forward again.

I looked at the batteries and one battery post had completely melted down and the cable was about an inch over to the side, and still connected and burning (small).

I hesitate to replace the batteries alone for fear that there is another problem other than the batteries.

What should I check or should I turn it over to a professional cart mechanic?

Hi, Ernest -
Don Stokes from Zap of New England says:

"Batteries in general heat up when they are being discharged quickly. This condition can cause the speed controller to shut down for a brief time and once cooled, start operating again. This can at times also cause standard lead acid batteries to "boil over", for a lack of a better term.

The batteries that are usually used for EVs are of the maintenance free variety called AGM batteries which are a sealed battery with the interior chemistry as a gel. These batteries are far less likely to leak due to charging and jostling.

If the batteries are creating a mess all the time, the charge controller may be using too much voltage to charge the batteries.

First, check the output voltage on the charger; it should be the same as your batteries. Next, don’t use the cart flat out for long distances, vary the speed so the batteries and speed controller don’t overheat.

Last, replace the old style liquid lead acid batteries with a deep cycle AGM battery."

Regards,
Lynne