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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."


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battey post burnup - post melting
by: Dave R. Weymouth MA

ONLY reason these posts burn out is that you didn't clean the post and clamp with the proper tools and tighten it properly. As to water coming out of the fill caps you got too much water in them Level should be about 1/4-1/2" below the ring. How do I kow? Drive a Chev pickup that uses 20 of them, previously had a Ford pickup that used 20, and both of my garden tractors use 6 apiece. Experience over many years. To learn these things with minimum pain you should join the electric automobile assn most of us drive home converted vehicles using T105 0r 125 size lead acids. As to charging, sounds as if you are or have been overcharging or the batts themselves are badly sulfated. Test them individually with a load tester. Voltmeter itself will not tell you much, a tester draws bout 100A and checks voltage that it would have in use.

by: Anonymous

I had exactly same situation as lst comment -batt cale burned into, replaced with new cable worked for 2 days and cart stopped sudden and the same batt cable and half of same battery post burned off . I had noticed after replacing batt CABLE THE cHARGER WAs not recording any charge. During the night I left Charger unplugged. This is a 2003 EZ Go Cart I bought used. Just my luck when buying used product.

burned off terminal
by: jedmeister

I had a battery cable burn off last month.To salvage it I drilled a small hole down the center of the terminal and screwed down the cable to the post. Works fine as a temporary fix till you can replace the battery. JED

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