Need help burning up motors

jeremykent

Ok I have a 2004 ezgo PDS cart 36 volt. Just rebuilt for a customer.
New batteries
New controller (stock) with red freedom plug
New solenoid
And was a rebuilt motor

The first motor got really hot and burnt the brush holder to the point it wouldn’t hold brushes

Replaced the motor with another one from the shop that had a fresh arm. Turn, new brushes and brush holder figured the first one was a bad build....

Now 3 days later I got a call with no travel and the same burning smell

The cart has been in service for 3 months now and all of a sudden I have been through now 3 motors in a week??????

Any suggestions

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BGW

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JohnnieB

Check F1 & F2 cables for worn through insulation where they are routed around frame.

Also check F1 & F2 cables and connectors for excessive resistance. Should be <1Ω from push on terminal to ring terminal.

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Something is causing the armature to draw excessive amps.

Running on low batteries will do that. (Never take them below 50% SoC)

Something partially shorting out the field winding will also do it.
With F/R in F, rear tires off ground and pedal on floor (3 or 4 seconds only) you should measure 2.7V +/- 0.5V between F1 & F2 at the controller and same voltage at F1 and F2 motor studs.

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jeremykent

Didn’t say it but all new cables too. Not to say they haven’t rubbed through. Picking up cart in the morning. Will check that first for sure.

hyper1

we had this happen to a 36v cart and it was a bad cable.

scottyb

I had this happen to a PDS years ago and turned out the customer was pushing the PDS unmercifully - downhill with no speed limit, big tires & added passengers off road. We went though 2 Bandit motors in 2 weeks.
This cart needs 48v to reduce amperage draw, a bigger motor, and a serious sit down chat with the operator about the care and use of a sepex drive system.
I even go as far as to suggest installing a motor temperature gauge. here > http://www.buggiesgonewild.com/elect...p-exist-5.html

There is always the person who will use a 36v PDS in a manner that will burn up the motor. He may not be a hot rodder.... he may pull a mower ... or turkey hunt. Slow going with big tires pulls a lot of amps. High amps mean high heat.
I hope this helps

jeremykent

Ok. Good news it wasn’t the motor. The pedal box switch was wet and the switch wasn’t working.....Shew.

Any how a quick thought on the motor. Are the armatures different between a series and regents motor. I sent both out at the same time and the tags were gone when I got them back. Either way doesn’t make sense it went for so long then this happened.

I did find out the security guards cart wasn’t lasting through the night and they were using this one. Might have something to do with it. No one is around to see him riding. Replaced a bad battery in his cart so I will see what happens.

scottyb

A note on security carts - a battery pack has about 110 minutes of actual run time on it. A guard who thinks he will drive the cart around for an 8 hour shift is the cart's worst enemy.