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Unread 04-11-2008, 11:26 PM   #1
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Default 97 regen motor problem

I bought a 97 club car with bad batteries. I removed the regen contactor and coil assb and ran the white wire directly from the motor to the controller as directed. I put new batteries in today and when I turned on the key the sol clicked and in a short time the motor was smoking a little and got very warm. I removed the motor tested the field studs for continuity to the case and was good. Cant get one of the long screws out to check brush end. may have to try again tomorrow. any help would be apreciated as to what might have happened ?Thanks Rick
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Unread 04-12-2008, 12:18 AM   #2
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Default Re: 97 regen motor problem

you should not have continuity to the case at all..

A1 and A2 should have continuity

f1 and f2 should have continuity

a1 and a2, to case should be no continuity

f1 and f2 to case should be no continuity

a1, or a2 to f1 or f2 should be no continuity...

any of those factors askew and you have a motor problem for sure...
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Unread 04-12-2008, 08:11 AM   #3
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Default Re: 97 regen motor problem

Thanks Phasetim
could a bad controller cause the motor to get hot?
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Unread 04-12-2008, 08:46 AM   #4
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Default Re: 97 regen motor problem

A bad connection or just overloading in general will get the motor hot also. If the controller was malfunctioning I suppose its possible but have never seen it happen.
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Unread 04-12-2008, 09:03 AM   #5
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Default Re: 97 regen motor problem

A random morning thought: does the motor have the wires coming off the end plate? Ive seen a series motor put in a regen car, that caused similar symptoms...
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Unread 04-12-2008, 12:10 PM   #6
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Default Re: 97 regen motor problem

I did all the continuity tests and it just as you said above. I pulled the arm and it is very clean, brushes look hardly worn. put the motor back in and again did the cont tests every thing checks out ok. I did not hook up the battery cables yet. there are wires coming out the end plate. I assume speed sensor and are connected to a gray plug which go to the controller plug.motor md 5BC59JB56251B 48 V 3.2 HP controller is EV4L48xB2. I also plugged the charger in with out the motor hooked up being careful of the motor cables. it turned on for a few seconds and then popped the breaker in the panel, it was on an extension cord though. Thanks again you guys for all your help.
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Unread 04-12-2008, 12:59 PM   #7
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Default Re: 97 regen motor problem

Id like to add the connections for the controller to the motor are and look correct
A1 To A1
A2 toA2
F1 to F1
F2 to F2
P to contactor
N to Batt -
contactor big posts is open with cables off
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Unread 04-12-2008, 02:30 PM   #8
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Default Re: 97 regen motor problem

I havent been able to charge my batteries since I brought them home. with the key off have 48 volts but I did a voltage test on the motor cables when I turn on the key and they all had 45 v except F2 was 2.9 v. my charger needs new diodes.
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Unread 04-12-2008, 04:22 PM   #9
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Default Re: 97 regen motor problem

My only other thought without having the car in front of me is a seized rear end not allowing that motor to turn, but if the car rolls easily thats not it..
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Unread 04-12-2008, 04:56 PM   #10
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Default Re: 97 regen motor problem

my controller has 3 cable connections on each side and a multi small wire plug, is that a common style because i havent seen one like it.Thanks again for all your help
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