Quote:
Originally Posted by barsss
Any ideas Gornoman. Battery connections are tight, will check motor and controller tonight. Do you think this could be a motor issue. That is the only piece of the puzzle that is not less then 3 years old. Need help.
Battery bought in 2009
Cables bought in 2009
Controller bought June 2012
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Too tight maybe?
As you can see in your photo, the stud is merely a hex-head bolt embedded in soft lead.
Trojan's tightness spec on that type terminal is only 95 - 105 lb/in, which is less than 9 ft/lb.
I use a screwdriver handled 1/4" drive to tighten battery stud bolts so I don't forget and accidentally over-tighten.
What do you cable ends look like?
My original ones looked okay, but were the lugs were the open ended type and corrosion got into the wire strands.
I run a stock (300A) controller and my tires are about the same height as yours (18.7") and my 2Ga cables with soldered-on, closed end lugs with the gap between lug and insulation sealed airtight, feel cool to the touch on a hot day.
What PDS mode do you run in?
Regen braking can pump a lot of amps through the cables.
Also, check for mechanical drag. (Stuck brakes, dry bearings, etc)
That will cause the motor to draw high amps.
Added: Those are open ended lugs on the cables pictured.