DPI charger plug gets hot

mhebert4224

In the last 6 months I have replaced 2 plugs that melted. I figured my kids were not engaging the plug fully. I stopped the kids from plugging the cart in and made sure the plug was plugged all the way in. Within 10 minutes the plug and cable going to charger starts to heat up and you can smell the wires heating up. Any suggestions? Would a charger do this if its about to go out? All connections look good on the cart. Should I look to change out the female plug on the cart? At a loss..

BGW

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smallblock450sl

Yes, definatly check the female receptical for damage/burnt plastic. Did you replace the cord end or the whole dc cord? I have found the cord end pins must be soldered in, not crimped. Good luck

mhebert4224

I only replaced the plug end not the cord. The first melt down was for bad connection but the last 2 issues the plug has been engaged all the way and female side of the plug looks clean. I will see about swapping the cord out and see if that helps.
Thanks

teecro

Couple of things here..
(A) Female connection is dirty, spray some WD40 in the connection then plug and unplug a few times, repeat the WD40 etc...
(B) The female connection is worn to the point of being a loose connection, repair or replace.
Both of these conditions will cause heat...

mhebert4224

Opened up the plug and its started to melt the negative side. I pulled on the
negative from battery side since it was hot as well. It pulled right out and was burnt as well. I plan on changing out the cord on the charger but what part do I order to change the female plug out on the cart? 11 G29

mhebert4224

I found the parts to swap out. Thanks for the replies!

mhebert4224

Update.
Swapped out the charging receptacle and new plug. Worked like a charm and no heat coming from cables. I did notice after about 6-7 hours of charging that I could hear a few batteries boiling. I checked the levels right after the install and everything was in line. Is this normal. Not sure I have ever heard a boil. It took a good 8 hrs to bring back to fully charged and kicked off the charger.

Volt_Ampere

It's not boiling - it's gassing. They are not hot. That is normal when the charger goes into overcharge - which it does to keep the batteries balanced.

mhebert4224

Thanks for the info.