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Unread 07-25-2013, 05:34 PM   #1
Not Yet Wild
 
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Default Cart quit running suddenly

Hello all, I replaced all 6 - 8v batteries and power cables last spring on my pre owned 1997 DS club car. Prior to today's total power failure while running uphill and going over a bump, the cart seemed to perform well when fully charged but an electric burn smell was present, mostly at low speed. It also seemed to lose power quicker than it should.
The cart is being used here in the blue ridge mountains of western NC. I have done a load test and the batteries are in spec.
What else should be checked to diagnose this problem?

The power cables from the motor and the motor itself were hot after the failure.

Appreciate any pertinent advice. First electric cart for me. The dealer I purchased it from told me he changed the motor to a higher HP version.

Thanks
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Unread 07-25-2013, 05:58 PM   #2
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Default Re: Cart quit running suddenly


Quote:
Appreciate any pertinent advice.
sounds like motor burned up
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Unread 07-25-2013, 06:07 PM   #3
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Default Re: Cart quit running suddenly

is it a series cart with a manual shift lever for f/r ?
if so then I would also inspect the f/r switch.
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Unread 07-25-2013, 06:16 PM   #4
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Default Re: Cart quit running suddenly

Most times on those series model carts when something burns you can find the source by looking at all the wiring and looking for melted insulation. There isn't as much complexity as regen carts and most of the electronics is in the open where you can see it
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Unread 07-25-2013, 10:11 PM   #5
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Default Re: Cart quit running suddenly

Agree with the guys who say check for burnt insulation/loose wiring. I've melted battery posts before when under too heavy of a load and had the exact issues you're having. You would think it would jump right out at you but sometimes it doesn't. Double check that all the cables on the batteries are tight and you didn't melt a post or some wiring somewhere when you were under load. A blown controller will smell burnt, but it's a NASTY burnt smell and usually leaves the cart undriveable. Had one literally POP and blow the back out once . If the F/R switch and all the other electronics and connections check out, I'd put my money on CTD's diagnosis: smoked motor.
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Unread 07-26-2013, 03:35 AM   #6
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Default Re: Cart quit running suddenly

Quote:
Originally Posted by sjtummillo View Post
Hello all, I replaced all 6 - 8v batteries and power cables last spring on my pre owned 1997 DS club car. Prior to today's total power failure while running uphill and going over a bump, the cart seemed to perform well when fully charged but an electric burn smell was present, mostly at low speed. It also seemed to lose power quicker than it should.
The cart is being used here in the blue ridge mountains of western NC. I have done a load test and the batteries are in spec.
What else should be checked to diagnose this problem?

The power cables from the motor and the motor itself were hot after the failure.

Appreciate any pertinent advice. First electric cart for me. The dealer I purchased it from told me he changed the motor to a higher HP version.

Thanks
check batteries for boil over, indulation and wire connection/ battery posts, then controller, then motor. just my 2cents
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Unread 07-26-2013, 08:09 PM   #7
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Default Re: Cart quit running suddenly

Thanks everyone for your replies. Without any prior electric buggie experience, I could use some suggestions for diagnosing the problem. Could it be the motor brushes need replaced?

With the cart chocked in my driveway, I pressed the throttle and while in forward and reverse it sounded like a solenoid was clicking.
What tests can be done to further isolate the power failure problem?

All battery connections are tight and batteries are less than a year old.


Thanks
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Unread 07-26-2013, 08:19 PM   #8
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Default Re: Cart quit running suddenly

jack up rear and jump the motor
Quote:
Originally Posted by roady89 View Post
1. Connect S1 to A2
2. Connect 12 volt posistive from a battery charger to S2
3. Connect 12 volt negative from a battery charger to A1
4. Turn on charger, observe , then turn off charger.

If motor runs its ok.
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Unread 07-28-2013, 07:41 AM   #9
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Default Re: Cart quit running suddenly

Thanks CTD. Should I disconnect the battery leads to the motor before performing your recommended test?
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Unread 07-28-2013, 07:46 AM   #10
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Default Re: Cart quit running suddenly

Good Info
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