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Unread 09-14-2012, 08:43 PM   #1
PBB
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Default EZ-GO PDS- charge wire getting hot

Have an 06 EZ-GO PDS. Batteries have gotten weak over time and then all of a sudden the cart quit and would not move. I found that the controller smelled burnt and replaced it. I also replaced the batteries withg new ones. The cart now runs fine and when you plug it in, the Powerwise charger goes up to 20 amps right away like it should for several minutes and then backs off to around 7-8 amps to finish charging. My only concern is that the white wire from the charge receptacle gets pretty hot right away. I do have the 60A in line charging fuse in place for safety. I dont think the charger wire and the controller where related in any way, but wanted to get a second opinion. I think there must be resistance somewhere in the charging wire??

Any help is greatly appreciated.

Thanks, PBB
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Unread 09-14-2012, 11:02 PM   #2
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Default Re: EZ-GO PDS- charge wire getting hot

take the charge receptical apart (on cart) and check for corrosion. they are bad about it. You may need to replace the complete wire. also check the brass connectors. make sure you have good contact. I have seen it only a couple of times. I replaced teh complete charge receptical and harness and the wire didn't get as hot. that recepitcal with harness is about $100 (from EZGO) if i remember correctly
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Unread 09-15-2012, 01:49 AM   #3
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Default Re: EZ-GO PDS- charge wire getting hot

Inspect the connectors on the charger cord and the receptacle on the cart. The female connecters on the cart can get worn or corroded and not make good contact and will often cause this. You can change the connectors(RADSOC) without changing the whole receptacle, unless the housing is melted. Make sure to remove one of the battery leads before disassembling the receptacle.
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Unread 09-15-2012, 06:34 AM   #4
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Default Re: EZ-GO PDS- charge wire getting hot

Put Run/Tow switch in Tow before doing any electrical disconnecting or connecting any wires or cables.

In fact, put in Tow whenever working on cart, unless you actually need to have the controller live for what you are doing.

The black and the white wire from the charger receptacle to the battery pack have an identical amount of amps flowing through them, so they should be identical in temperature, and neither should get more than warm, and if they and their connections are good, they don't even get warm.

If they are warm, there is resistance and when there is resistance there is a voltage drop, which in turn means that your new batteries are not being as fully charged as your charger is capable of charging them.

I found that the battery end of the black and white wires on my cart were corroded within the wire itself, so I cut them back until I found clean tinned copper and attached new ring terminals that I both crimped and soldered.

The female Radsoks in the receptacle are expensive, so you might want to try cleaning them first. Spray them with a good contact cleaner and plug the charger plug in while they are still wet. Do it several times. Have either the black or white wire disconnect from battery pack while doing this.

I cleaned my male and female Radsoks in a brass tumbler using crushed walnut media and NuFinish. If you, or you have a friend/neighbor that reloads ammo, you can do same or similar.

Since fuses have to have resistance to work, I also eliminated the 60A fuse in the white wire. My charger output is fused, the outside of the positive Radsok is insulated and I don't stick conductive objects in the cart receptacle. However, if you have kids around...

Hope this helps.

BTW - here is how to break those new batteries proper so they reach the maximum storage capacity: http://www.cartsunlimited.net/Batter...n_Methods.html
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Unread 09-15-2012, 07:54 AM   #5
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Default Re: EZ-GO PDS- charge wire getting hot

Thanks for the insight guys. That is what i had planned to do this morning, just wanted a second opinion. I have a couple extra charge receptacles so i may just swap it out. There doesnt seem to be any corrosion on the terminal ends at the battery, so it must either be in the wire itself or in the female receptacle. Thanks again. I'll post some pics of my work once I get past this new member thing.
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Unread 09-15-2012, 08:13 AM   #6
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Default Re: EZ-GO PDS- charge wire getting hot

The Ohmeter function of an inexpensive DMM is useful. Any ohm reading at all is too much.

I can't remember off hand if the black and white wires are 8Ga or 10Ga, but in either case the intrinsic resistance is less than 0.001 Ohm per foot, and the length of the two combined is only about 5 or 6 feet, so a reading of 0.01 Ohm or more needs to be corrected.

Also, the voltmeter function while charging. Any voltage drop across any wire, connection or component, is too much.
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Unread 09-15-2012, 11:24 AM   #7
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Default Re: EZ-GO PDS- charge wire getting hot

I have found that a 22 caliber rifle bronze cleaning brush is great for the radsok terminals. I grind off the little bit of the wire twist so the bristles go all the way to the end of the brush. You can do a great cleaning without having to take anything apart! Mine are soldered on anyway, so I can't take them apart ( at least easily ). You can get these cheap at Walmart or any gunshop. Hold it with pliers and only twist clockwise, while moving it in and out.
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