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Old 07-26-2014, 11:48 AM   #6
JohnnieB
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Join Date: Jun 2011
Location: West Virginia
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Default Re: Motor & Solenoid to hot to touch

1. Good, it is giving an error code. The next time it happens, count the number of blinks. The blinks occur at 1/2 second intervals, then there is a 1 second pause and the blink sequence repeats. (4 blinks is overtemp --- 6 blinks is undervolts.)

What were you doing with the cart immediately prior to it shutting down?

Building a reliable cart is an admirable goal, something most of us strive for.

2. That isn't excessively hot. Probably no more than 160F.

3. Mount the Run/Tow switch in a plastic box attached to the underside of the seat lip near the controller and leave to cover off.

4. Sounds like modest tasking. Unless you plan on creeping through the woods at walking speed or less, or climbing really steep hills with the family on-board, a properly upgraded PDS cart will met those needs.

5. The DCX400 increased the number of amps the motor can draw by 33.3%, the stock solenoid whose contact are rated at 85A was replaced by a solenoid with 200A contacts and the 5 year old OEM high current cables with crimp-on terminals were replaced with 4Ga cables with silver soldered terminals, so the majority of the bottlenecks in the amp delivery system have been eliminated and the motor is now free to draw the amps it needs to produce the torque being called for.

6. That means the batteries are 2 years old, have been well maintained in the past year, but unknown for the first year.
There is a possibility you may have a battery issue.

What is the make and model of the batteries and what is the pack voltage when measure 12 hours after the charger shuts off? (Should be 38.2V)

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As pointed out in #5 above, the motor can draw a lot more amps now than it could before, so it is going to run hotter since heat generated increases exponentially as amps flow increases linearly. (There is more to it than that, but you should get the idea)

If the 23" tires are the low pressure type (max inflation pressure under 10 PSI), they take even more amps to turn than high pressure 23" tires (max inflation pressure over 20 PSI) and you most assuredly need more motor to turn them.

The 23" tire height alone is costing you about 22% of the available torque where the rubber meets the road, so I would go with a motor that generates more torque. A D&D 170-501-0001 produces 10% more torque than the stock PDS motor and a D&D 170-502-0001 produces 40% more.
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