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Old 05-26-2010, 08:00 PM   #1
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Default Is it typical for end of charger cord to get hot?

Now that I am using my cart daily I have noticed that the end of the charger cord that attachés to cart gets quite hot especially in the early stages of charging. Is this a normal situation or should I be looking for a problem? If you have read some of my threads this cart is all pretty much new in regards to electrical parts. The only thing I can see is that the charging cord feels week just before the section that plugs into cart. Maybe some of the wire strands have broken due to years of use. This is a 1995CC with a Powerdrive charger that came originally with cart. The batteries are also new.

Thanks
Phil
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Old 05-26-2010, 08:46 PM   #2
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Default Re: Is it typical for end of charger cord to get hot?

Two things to consider Phil,
The beginning of the charging cycle is when the highest amps are being delivered and resistance causes heat.
If you can get away with it I would cut the charging cord back about a foot and reinstall the plug after you clean both ends of the plug and recepticle.
If you can't shorten it you might need to replace it and if that's the case step up to the next gauge on wire size.
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Old 05-27-2010, 07:00 AM   #3
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Default Re: Is it typical for end of charger cord to get hot?

Warm is normal, but hot to the touch is bad. Check the connector end and make sure that your plug terminals are clean and not pushed in. If you can take apart the end, look at the crimp/solder and inspect for corrosion or frayed wires. If your cord looks good, then inspect your charcge port .lift the seat of the cart and inspect the wires going from the charge port to the battery. They should be clean with no corrosion or frayed ends. You may need to pull the wire out of the loom to inspect the whole length. I have seen these wires held on by 3-4 strands of wire, or wrapped around a battery post with the nut tightened to hold it on. If your connections to the battery aren't perfect, you will get a hot cord and the wires inside the cart are probably getting very hot too.
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Old 05-27-2010, 11:28 AM   #4
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Default Re: Is it typical for end of charger cord to get hot?

Sounds like a bad connection. Electricity runs on what is called the skin effect. Meaning it needs surface area to pass along. A high current needs a larger surface area to pass across. If you have a bad connection as others have said, then all the current your charger is sending to the batteries is having to be pushed across a smaller area and heat will definitely be factor. If it feels loose I would cut it back or replace it. You could burn/melt something else up if you don’t.
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Old 05-27-2010, 01:13 PM   #5
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Default Re: Is it typical for end of charger cord to get hot?

I would say your cord is failing from all the years of use.
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Old 05-28-2010, 12:15 AM   #6
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Default Re: Is it typical for end of charger cord to get hot?

Thanks guys. That was my gut feeling. I think it is a little bit of everything you guys mentioned. I ordered today a new charger cord and a new cart receptacle. I think I will replace the wires from the receptacle also. I have to much invested in the cart already and would hate to burn it up.

Thanks again Phil
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