Problems during solid state conversion

[jjance]

I've searched and I can't find the diagram on how to hook it up using 2 batteries. Maybe somebody else will have it. Can you push the cart easily. That should tell if the motor is seized.

[Sergio]

To test if the motor is seized, put one wheel down and turn the other wheel by hand.

That will force the motor to rotate thru the differential.

[scottyb]

This is the series motor test if needed.

[ecaldwell78]

Well the only thing i was able to do last night was roll the cart, it rolls fine, and i jacked up the driver side rear and it does turn both directions, although it feels like a brake is dragging. It will spin free for maybe 3/4 revolution then get a little tough for 1/4 turn, and so on. I didnt' get a chance to try the pass. side yet nor put battery power to the motor just yet. I can say for certain that i do NOT have a brake dragging though.

[Sergio]

The wheel should not rotate free as it is turning the motor.

Here are a few tests you can do that do not require any specialized tools:

Lift one of the rear wheels of the ground, slowly turn the wheel, for each 1 full revolution of the wheel, the motor will turn 6 full revolutions.

The important part here is to listen to the motor for any sounds of dragging or scratching metal.

If You feel any part of the rotation that is "harder", if it is coming from the motor, it will happen 6 times per wheel revolution, otherwise is a brake or friction in that axle side.

Lower that wheel, then lift the other wheel and do the same test.

Now lift both wheels off the ground, slowly turn one wheel clockwise, the wheel in the opposite side should proportionally turn counter-clockwise. That is because the friction losses in the opposite side axle/hub/brake are less than the mechanical advantage of the motor connection to the differential, so the motor should not turn.

Do the same test from the other wheel and notice if the opposite wheel is also turning proportionally, if not, the opposite side is dragging.

[UncleJerm76]

Originally Posted by Sergio

It may a little late for You, but as a reminder to other folks reading this post: Never run a DC Series motor unloaded.

Hey ScottyB, your instructions were great and easy to follow. Do you remember if this warning was in there?** I cant remember all the instructions that far back but I have them all at home and can look at them. Glad I didn't do this!

**Might be a good opportunity to add this warning to the instructions if they aren't already in there.

[ecaldwell78]

Well fellas, I just did the motor check per Scotty's diagram and the motor does indeed turn! Bittersweet because now I don't know what the heck to do.

[Sergio]

Good news on the Motor

I am not familiar with the package you have, what model controller does it have?

[CCFanatic]

"Pkg C54 Our most popular kit for Bigger Hills and Heavier loads.

This super duty solenoid and controller combo is big enough for most aftermarket motors.
Can be used with stock motor

Same kit as C52 above but 400 amp super solenoid which runs on 36 volts now and 48v later. This solenoid has bigger higher quality contacts for heavier loads.

This kit includes the throttle conversion kit, linkage, & install brackets & hardware,
PLUS the Off-road capable 500 amp FSIP GE adjustable controller. a 400 amp Super duty solenoid kit, & the potentiometer"

[Sergio]

I assume that is the 51-42S500NN0S controller and a 0-5kΩ potentiometer.

That is a pretty straight forward setup and Scottyb probably has all of this written down, but here are a few tests:

1) Controller Activation

Set the meter to 200vDC and measure from Pin 1 on the controller to pack negative.
You should get 48v when the pedal is pressed and micro switch closses.

2) Throttle Input:

Set the meter to 20kΩ.
Disconnect terminals #2 and #3 from controller
Measure the resistance between the wires that were connected to pin #2 and Pin #3
You should get 0 to 5kΩ from Pedal Up to Pedal down.

3) Motor output

Set meter to 200vDC
Measure voltage between Controller B+ and M-
You should get 0v to 48v from pedal up to pedal down.

This will get us started.