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Unread 09-21-2012, 06:47 PM   #1
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Default Powerwise charger w/ Club Car round three prong charger plug HOT!!

Powerwise charger w/ Club Car round three prong charger plug. I noticed today that the round 3 prong part that plugs into the cart is very hot.. the cable from the charger to the plug is warm and the 2 (8 or 10) gauge cables on the (female?) side is pretty warm but only close to the plug. I have the charger plugged into a APC 280 Office bk up surge protector (which I noticed has been turning off when I go down to check on the charge)

I also notice that the Club car 3 prong plug's plastic is brittle and pieces are coming off.

Is this a bad connection or?

EZGO 2000 PDS Stock 36v.
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Unread 09-21-2012, 08:17 PM   #2
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Default Re: Powerwise charger w/ Club Car round three prong charger plug HOT!!

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Originally Posted by lawnripper View Post
Powerwise charger w/ Club Car round three prong charger plug. I noticed today that the round 3 prong part that plugs into the cart is very hot.. the cable from the charger to the plug is warm and the 2 (8 or 10) gauge cables on the (female?) side is pretty warm but only close to the plug. I have the charger plugged into a APC 280 Office bk up surge protector (which I noticed has been turning off when I go down to check on the charge)

I also notice that the Club car 3 prong plug's plastic is brittle and pieces are coming off.

Is this a bad connection or?

EZGO 2000 PDS Stock 36v.
Definitely a bad connection! A bad connection anywhere will cause heat. That's why battery posts sometimes melt. Take your plug apart and see if you can clean the contacts. Worst scenario is having to replace the plug and the receptacle. I know a few folks who have used a plug and receptacle for a clothes dryer, with good results! I'm not sure which set would cost more, the originals for the cart or the 240V plug and receptacle.
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Unread 09-21-2012, 08:18 PM   #3
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Default Re: Powerwise charger w/ Club Car round three prong charger plug HOT!!

I would suggest cleaning all of the connections, maybe even a very light sanding. Heat is a definite sign of resistance.
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Unread 09-21-2012, 09:15 PM   #4
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Default Re: Powerwise charger w/ Club Car round three prong charger plug HOT!!

Right on guys! thanks for the replies! I just took the plug apart and the wires were brittle, the insulation on the smaller cable was black (instead of red) and kinda melted a bit. The actual male pins were loose from the plastic mold of the plug, and more piece of plastic are crumbling off including the guide piece on the side of the plug that lines up with the carts receptacle. I am gluing some pieces bk together, snipped the wires back until I found good wire, and am cleaning out the connections.. scraping and contact cleaner.

I was wondering if I could make my own plugs and even cable..I would like to know more about using a good 240v F & M plug. And would like to know if I can replace the 3 cables as well.. if so what type and gauge? Looked like 2 10's and a 12 are in there?

Living in the jungle.. ordering the replacement parts and waiting for someone to get it here could take a while and I need to keep this thing charged.

thanks again!!
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Unread 09-22-2012, 02:20 AM   #5
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Default Re: Powerwise charger w/ Club Car round three prong charger plug HOT!!

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Originally Posted by simple man View Post
I know a few folks who have used a plug and receptacle for a clothes dryer, with good results! I'm not sure which set would cost more, the originals for the cart or the 240V plug and receptacle.
I've read about folks having done so. My warning for doing something like this is that the receptacle was not designed to be plugged and unplugged on a daily basis. How many times a week does a dryer or oven get unplugged and replugged? If you look at the construction of a RADSOk vs. a receptacle, the difference is obvious. Of course, if you only drive it once a week, you may get years out of it.
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Unread 09-22-2012, 08:13 AM   #6
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Default Re: Powerwise charger w/ Club Car round three prong charger plug HOT!!

Quote:
Originally Posted by lawnripper View Post
I was wondering if I could make my own plugs and even cable..I would like to know more about using a good 240v F & M plug. And would like to know if I can replace the 3 cables as well.. if so what type and gauge? Looked like 2 10's and a 12 are in there?

Living in the jungle.. ordering the replacement parts and waiting for someone to get it here could take a while and I need to keep this thing charged
I also recommend using something designed to be plugged and unplugged often, but when you are out in the middle of nowhere, you gotta do what you gotta do.

Might be able to help you find the cable though.
Cables with all the wire the same size are cheaper than those with mixed sizes.
There is only about 20A, so 12Ga will suffice and SJOOW 12/3 should work.
Here is an on-line source that sells cable by the foot in small quantities.
http://www.wesbellwireandcable.com/SJOOW.html
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Unread 09-23-2012, 04:51 PM   #7
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Default Re: Powerwise charger w/ Club Car round three prong charger plug HOT!!

hey guys thanks once again for your input and help!! Love this site!

I cleaned,sanded, scraped all contact pins etc.., snipped the bad part of the cable/s, soldered the ends nice and tight, epoxied the loose pin and broken guide piece. Looks like it worked.. Charged it up yesterday and it charged it all the way! The plug, receptacle and cables were verily warm. I will be ordering a replacement parts soon! Thanks again!

ps. can anyone here recommend a good on cart charger made for the road(bumpy roads)?
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Unread 12-30-2012, 12:11 PM   #8
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Default Re: Powerwise charger w/ Club Car round three prong charger plug HOT!!

Where can I order the og round 3 prong receptacle for my 36v 2000 pds w/powerwise charger?
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