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Unread 10-23-2015, 05:44 PM   #1
Gone Wild
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Default Cart Still Running Hot, Still need help, please

I had a thread going about problems with my CC here:

Repair or replace my motor 36V motor with 48V?

It kind of died after I got some good advice, which I have followed, but still can't get the cart running right.

I have a 1993 Club Car DS converted with the following upgrades:

6 - 8 volts - 48V cart (two batteries in bagwell)
700 amp FSIP controller
400/1000 solenoid
Potentiometer
2 g cables
Heavy Duty F/R switch
4" lift kit
22X10X10 tires
Rear seat

I did not upgrade the motor when I upgraded everything else. After about a year or two of running it, the motor burned up. I replaced it with a PlumQuick Bandit motor. Bad news - it still runs hot. Good news - I have not burned up the motor - yet. It runs hot even if I turn the controller all the way down, both on the current limit and the acceleration.

I've backed the brakes all the way off. Same result - run an 1/8-1/4 of a mile and it runs hot (can't find the temperature sensor or I would know how hot, but abnormally hot).

I cannot identify the problem. Only things I can think of now are: (1) some of type of cable or battery damage when the last motor burned up (but the cables and batteries look fine); (2) a damaged potentiometer; (4) a damaged F&R; (5) a problem with the rear end creating drag somewhere; or (6) too high of a gear ratio (if that's the right term) for the motor on the differential.

Like I said, I have inspected the cables and wiring and don't see anything burned up. The batteries look fine. It runs, so I don't know how the potentiometer or F&R switch would play a role. Only thing I can possibly think of is the gear ratio. I don't know.

If you have any ideas, please let me know. Cart has been down a few months now and hunting season is already on us, so I'd like to get it up and running soon.
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Unread 10-23-2015, 05:57 PM   #2
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Default Re: Cart Still Running Hot, Still need help, please

Quote:
...It kind of died after I got some good advice...
I'm sorry, but you got to admit that is kinda funny.

Without knowing anything about carts, just life in general, I would guess the horse power of the motor can not push the cart. You could be right the gearing might be too much for it given the diameter of the tires. On the other hand, once you get up to cruising speed the need for horse power would drop off and the motor would consume less energy.

The basics say heat is generated by resistance. Put a 220V line into a light fixture and see what happens Maybe giving that motor all it could swallow wasn't such good advice after all.

If you go back to basics, simple engineering would setup a cooling fan to decrease the amount of heat. A couple of CPU fans on a switch might make you sleep better at night.
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Unread 10-23-2015, 06:26 PM   #3
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Default Re: Cart Still Running Hot, Still need help, please

"Without knowing anything about carts but , here's what you should do .... "

The engineers at FSIP and PlumQuick have weighed in on this cart's problems so may somebody who knows nothing about DC drives can fix it.

I re read the original getting hot thread and this statement caught my attention (again)
"Well, before I had issues, I was getting 25 mph and no problem with hills out of that 36 volt motor."

I have done hundreds of these upgrades and never have I or any of my customers gotten 25 mph out of a stock motor on 36 or 48v - NEVER. Somethings fishy - either high speed gearing or high speed motor. But not the usual 36v stock motor on 36v, that would = about 14-16mph on 22s.

So where is the other nearly 2Xs the speed coming from? And maybe - just maybe this is causing the excess heat.
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Unread 10-23-2015, 08:36 PM   #4
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Default Re: Cart Still Running Hot, Still need help, please

After looking back may I ask how are you determining it is running hot and how hot was it running before when it was running so fast? You are running a 36 volt motor at 48, my assumption at these speeds that is a lot of rpms as Scotty suggested. There is a thread hear that shows you how to determine gear ratios.
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Unread 10-23-2015, 09:06 PM   #5
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Default Re: Cart Still Running Hot, Still need help, please

A 93 DS motor will not run 25, except down a long steep hill (like a cliff)
How hot are we talking here? Like burn your skin, cook an egg, or just it seems hot to me? And what else is hot? The wires hot? The controller, the solenoid....the devil is in the details
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Unread 10-23-2015, 10:21 PM   #6
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Default Re: Cart Still Running Hot, Still need help, please

I agree with Scotty. It sounds like it's got a high speed gear set. Try putting some regular size golf car tires on it and drive it around and see if it gets hot (just for test purposes). I had a lifted cart with 23 inch tires and high speed gears in the shop one time and it was doing the same thing yours is doing. We had a set of small tires, 16 inches tall I believe. They're used for shipping golf cars in 18 wheelers. Very short and narrow to allow 2 carts to side next to each other in the trailer. After installing the 16 inch tires, everything operated much like a factory golf car should behave. No heat and normal speeds.
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Unread 10-23-2015, 10:22 PM   #7
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Default Re: Cart Still Running Hot, Still need help, please

I emailed him a test procedure so we could find the rear end gear ratio for sure.
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Unread 10-24-2015, 10:44 AM   #8
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Default Re: Cart Still Running Hot, Still need help, please

Last week I put a speed app on my phone and took my cart for a wide open throttle ride 17 MPH First and probably the last time i'll ever put my foot to the floor in it but I was impressed
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Unread 10-25-2015, 09:34 AM   #9
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Default Re: Cart Still Running Hot, Still need help, please

Thanks folks. Going to try this tomorrow and report back. The speed I recorded was off an iPhone app but based on its comparison to a car speedometer it seems correct. Hopefully this is it. Will let u know.
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Unread 11-05-2015, 01:01 AM   #10
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Default Re: Cart Still Running Hot, Still need help, please

Tested the gear ratio per ScottyB and Plum Quick:

Remove motor
Jack up one side or jack up both, but if you do both, hold one wheel still.
Remove wheel.
Mark drum
Mark shaft
Count revolutions of shaft per one of tire

We got 6:1 holding one wheel still. Tells me the problem is a high speed gear. Can't find a stock one right now. Will keep looking.

There is 98 Club Car Kawasaki at the shop and that may have the same rear end as a 93, so going to look at that gear and possibly try it. If it's not right, will just keep looking online.

Thanks for all the help. Will update later in case someone ever has the same problem.
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