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Unread 08-26-2014, 02:47 PM   #1
Getting Wild
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Default CC electric motor keeps burning up

I have a 2008 CC 48V. Serial # AQ0848-985439
I just burned up my 3rd motor. The first 2 were from PlumQuick and I decided not to install the 3rd one they sent me. Instead, I bought one from D&D Motors and it lasted for 5 months before burning up.
I have replaced EVERYTHING on the cart except for wiring harness and OBC(which is bypassed).
Local shop tells me this is normal for some of the IQ carts. I find it hard to believe. I bought an infrared heat gun and would check motor temp constantly on the last motor that was installed. Temps would get to 180 and I would stop and I would stop and let it cool down. It would get that hot only driving it less than a mile on flat ground.
The cart has 4" lift
22" tires
Backseat/fold out bed
8 - 6volt batteries (2 in bag well) bought new 2/2014
1/0 welding cable to all batts and motor
High speed/high torque DD motor 502
DCX 500 IQ/TS controller
800amp solenoid
New brakes- definitely not dragging and free spinning
I was thinking on replacing the whole main wiring harness next and possibly a new OBC as well???
If anyone might have the slightest idea on what's making it run hot, I sure would appreciate the input!
Thanks for any help in this matter,
Troy
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Unread 08-26-2014, 02:51 PM   #2
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Default Re: CC electric motor keeps burning up

Controller programming is a big factor in sepex drive units.
Can you show how the controller is programmed?
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Unread 08-26-2014, 03:44 PM   #3
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Default Re: CC electric motor keeps burning up

In conjunction with scotty I was told this about the controller making a big difference, also never stall the motor.

Hunter, so I'M assuming you take it off road, has it ever stalled on you? I was warned about the heat issues, I guess that is why the hunter guys like the old series motors better, all torque, don't get as hot but suffice speed. I guess I'll find out soon enough myself as I have an Executioner from PQ but I don't off road much just very hilly where I use it. It does get hot, I'll continue to use it, If it burn up then I'm converting old school LOL, I have no choice it is hilly where i use it.

That said, how is the rear end?
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Unread 08-26-2014, 11:27 PM   #4
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Default Re: CC electric motor keeps burning up

Quote:
Originally Posted by scottyb View Post
Controller programming is a big factor in sepex drive units.
Can you show how the controller is programmed?
I don't know how it is programmed. It came from DD preset. I assumed they set it up with the cart setup I have. I have to call them tomorrow anyway and check on that too.
My solenoid is a 400/1000amp, not 800amp like I posted earlier. It turns out it's bad also. I haven't checked my Mcor yet. I have replaced everything 5 months ago and looks like I might be doing it all over again. Very frustrating!

Scooterman, I haven't taken it off-roading yet but had plans to as soon as hunting season started. Everywhere around here is pretty much flat ground with an occasional little hill, if you want to call it that. It has never stalled on me with the upgrades. Back when it was stock, it would stall out and I would have to wait 5-10min before it would go again. I am very happy with the upgrades except for the heat issue. the cart tops out at 31mph and has crazy torque. I would sure love to get this issue resolved.
The rearend is in great shape also. Fluids were changed (still looked clean) and new brakes installed. No brake dragging and its free spinning no prob.
I had the Bandit upgrade first from PQ. And after they replaced my motor twice in a month, they said my warranty is void cause there was something wrong on my end somewhere. So I still got a new one in the box that I never opened from them. I figured I try something different and went with DD. It lasted 5 months. A little better than the last two.
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Unread 08-27-2014, 12:08 AM   #5
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Default Re: CC electric motor keeps burning up

Sounds like you have covered just about everything. Years ago I had a car that kelp burning up starters. Turned out when I installed them and tightened the bolts the started shaft was pressing too hard inti the bell housing fly wheel slot. A few washers under the flang of the starter and never had problem again. Could be the motors are pressing too tight into the rear end binding the end play in the motor shaft. Don't know how to check that.
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Unread 08-27-2014, 09:15 AM   #6
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Default Re: CC electric motor keeps burning up

I checked that already. The second motor I installed wouldn't butt all the way flush without tightening the bolts down. Turned out that I had too much anti-seize on the shaft and it was hydro locking up or something of that nature they called it. I'm just gonna order another wire harness and go from there.
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Unread 08-27-2014, 09:19 AM   #7
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Default Re: CC electric motor keeps burning up

Are you by chance doing a lot of creeping around or very slow driving with this cart?

31mph sounds crazy fast for a torque motor can you determine if your cart has high speed gears in it. tall gears would put additional load on the motors.
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Unread 08-27-2014, 09:20 AM   #8
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Default Re: CC electric motor keeps burning up

Your reply reveals possible issues, I agree again with Scotty, the programming needs to be checked, at 31 mph and crazy torque you're pushing the motor beyond its capabilities, melting it up internally.
I recommend you go with a high torque motor, surcifice speed, you won't regret it. 31 Mph is unsafe for a cart unless you redesign the entire suspension and transfer the center of gravity.
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Unread 08-27-2014, 09:31 AM   #9
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Default Re: CC electric motor keeps burning up

I'll third Scotty and Scooter, on the Alltrax DCX if you do not program the field mapping for the correct motor you will either burn up the motor or the controller. You can program it yourself with the correct software and cable. I suspect this is your issue, along with pushing the cart to hard.
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Unread 08-27-2014, 09:35 AM   #10
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Default Re: CC electric motor keeps burning up

It's possible but very unlikely that D&D programmed the controller wrong for the motor. This motor should run this cart around 20-25mph, generally speaking - so I suspect high speed gearing has been installed.

Can you test to determine the rear end gear ratio?
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