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Unread 11-21-2015, 12:39 PM   #1
Not Yet Wild
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Default 91 CC DS 36v Project

Hey All,
1st, Thanks ScottyB for the upgrade kit for my 2003 DS that has gone from mild to wild!
I picked up my next project, but I wonder if I can maintain it for a while before converting. It's a 91 DS 36v resistor that has a small lift & knobbies with a back seat & batteries that are 2-3 years old. The previous owner said he tried to pull to much weight & the motor went up in smoke...
I charged the battery pack overnight which enabled the cart to barely move forward & reverse (so probably not a bad motor after all), but I could feel a lot of heat & a little hot smell coming from the resistor row. I shut it down & started reading threads on BGW because I know nothing about that type of configuration. If the batteries are fully charging and the motor barely turns but the resister coils overheat under the load, what say you?
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Unread 11-21-2015, 12:55 PM   #2
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Default Re: 91 CC DS 36v Project

Brushes are an overlooked link in the system,
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Unread 11-21-2015, 02:08 PM   #3
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Default Re: 91 CC DS 36v Project

Elaborate please?
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Unread 11-21-2015, 02:28 PM   #4
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Default Re: 91 CC DS 36v Project

Quote:
Originally Posted by Big Jack View Post
Hey All,
1st, Thanks ScottyB for the upgrade kit for my 2003 DS that has gone from mild to wild!
I picked up my next project, but I wonder if I can maintain it for a while before converting. It's a 91 DS 36v resistor that has a small lift & knobbies with a back seat & batteries that are 2-3 years old. The previous owner said he tried to pull to much weight & the motor went up in smoke...
I charged the battery pack overnight which enabled the cart to barely move forward & reverse (so probably not a bad motor after all), but I could feel a lot of heat & a little hot smell coming from the resistor row. I shut it down & started reading threads on BGW because I know nothing about that type of configuration. If the batteries are fully charging and the motor barely turns but the resister coils overheat under the load, what say you?
I would raise the cart rear wheels and see if the motor runs with light load, stalling it could have damaged the brushes, could be a lot of things I guess,...
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Unread 11-21-2015, 06:21 PM   #5
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Default Re: 91 CC DS 36v Project

time for new motor
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Unread 11-22-2015, 12:24 PM   #6
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Default Re: 91 CC DS 36v Project

So CTD & GK, are you saying that a potential motor problem itself would cause the coils to overheat?
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Unread 11-22-2015, 01:48 PM   #7
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Default Re: 91 CC DS 36v Project

it could, restorers heat up anyway till full power is applied. then they are by passed
smoke coming out of motor biggest clue , no power also
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Unread 11-22-2015, 07:49 PM   #8
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Default Re: 91 CC DS 36v Project

Big jack, those resistors will get reall hot unless WOT like crash said. They get hot enough to cook bacon. Literally, I tested mine like that before I converted.
The biggest problem with the resistor set up I had was the overheating and melting of the supporting wiring & components when cruising at low speeds.
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Unread 12-29-2015, 10:18 PM   #9
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Default Re: 91 CC DS 36v Project

GSF & CTD: thanks for the tips so far.
Ok, I lifted the rear end of the cart, pressed the pedal, & it seemed to perform as expected, with no excessive heat generated at the resistor coil...
Since the previous owner said the motor went up in smoke, that is what you mentioned CTD??
So motor functions when lifted, but under load, nothing but heat... Resistor problem???
Is that DIY repairable or should I just work again with Scotty on a conversion?
My intent is to eventually convert, I'm just trying to put it off a little longer... I just worked with Scotty on my '03 DS project, hoping for a little reprieve...
What say you?
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Unread 12-29-2015, 11:48 PM   #10
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Default Re: 91 CC DS 36v Project

you could pull the motor and look it over, could be brushes burned up
changing brushes is not hard
also a local motor shop could do the motor or tell if it is dead
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