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Unread 03-29-2016, 06:10 PM   #1
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Default 700amp controller melting wires

I just got a 2000 48volt ds and it's had money thrown at it my problem is it's melting the side from the wires and coming loose glowing red at the motor and I'm really almost to my wits end with this thing is there something I'm missing or do I need a smaller controller maybe someone just bought all the most expensive things trying to be the best or what it will run 30mph flat out that's cool but rebuilding the wires and not riding is killing me thanks for the help guys
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Unread 03-29-2016, 06:16 PM   #2
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Default Re: 700amp controller melting wires

what size gauge wires are you running?
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Unread 03-29-2016, 06:16 PM   #3
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Default Re: 700amp controller melting wires

What kind of motor is it. You may have a loose terminal inside the motor. If the motor lug has ever turned then most likely yes. Could also be the Forward reverse (F/R) switch causing issues. You definitely need a H/D F/R switch to handle that. Need AT LEAST 4 gauge cable preferable 2 or better.
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Unread 03-29-2016, 06:18 PM   #4
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Default Re: 700amp controller melting wires

2gauge wires and it has a HD FnR switch I always put a wrench on the retaining nut on the terminal when tightening the wires but they are loose how do I tighten them
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Unread 03-29-2016, 06:25 PM   #5
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Default Re: 700amp controller melting wires

If they are loose then at some point they may have turned/twisted. If the lug got twisted Ive seen those wires (at the motor) burn. Once they do that and get hot its too late. If in fact it has twisted and the wires melting its to late to just tighten it. Only way to really be sure is to disassemble the motor and take a peek or have a motor shop take care of it for you. Taking the motor off isn't that big a deal but taking the motor apart can be tedious. If your not comfortable taking it apart your better off taking it to a motor shop. Most people dont have the tools for the repair but a motor shop will.
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Unread 03-29-2016, 06:26 PM   #6
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Default Re: 700amp controller melting wires

^^^^^^^^x2
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Unread 03-29-2016, 06:31 PM   #7
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Default Re: 700amp controller melting wires

It can't be any worse than rebuilding a starter could it? I am Confident I can do the work just never delt with anything like this
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Unread 03-29-2016, 07:22 PM   #8
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Default Re: 700amp controller melting wires

when you take the bolts out motor/trans-axle its sitting on the spline , it slides off about a inch and be ready to catch a 50lbs motor.
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Unread 03-29-2016, 07:47 PM   #9
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Default Re: 700amp controller melting wires

Got it apart easy no big deal my studs the plastic insulators are melting and the retainer nuts just spin like the threads are burnt out what now I could say some colorful things about the shop I bought this thing from
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Unread 03-29-2016, 08:21 PM   #10
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Default Re: 700amp controller melting wires

If its the brush lug you should be able to get new brushes with the insulators. (Or you could TRY to re-attach) The brushes could be toast as well. It could have fried the brush holder to, you'll just have to tear down and inspect. If its a field coil lug same thing...you can "try" to re-attached but may need new. Motor shop might have something better to re-attach.
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