Advice - EZGO PDS Motor Replacement

[JohnnieB]

I used the rubber bumper from my old motor, so it already had splines formed on its OD and went in the new motor shaft easily. You might have to tap a new one in. Use something blunt like a 1/4" drive or 3/8" drive extension.

I think the wires are 18Ga, but 20Ga would work, they don't carry much current.

Fortunately, I don't need the other end of the wires terminated. Just have to figure out how long the wires need to be and what color wire goes to which pin.

My old motor was really stuck on tight, so I was fairly liberal with the anti-seize, but didn't go overboard.
I "painted" a thin coat on with an acid brush, to both the inside of motor shaft and the outside of the differential input shaft.
I bought a bunch of something similar to these at HF a while back and the come in handy for many things. They just get tossed when I'm done with whatever project I use them for.
http://www.harborfreight.com/36-piec...hes-41338.html

Yes. let me know if the will build the adapter.

[mdavey]

Thanks Johnnie!

[mdavey]

Hey Johnnie,

Well, I ended up going with the new spline bumper and the anti-seize compound. Everything went together nicely. I also got the DT06-3S-Assy and crimped on the wires (black/black, red/red, and white/green). The connection seems good. I did ask about the custom cable, but the answer was nope.

Put everything back together and the cart moves!!!!! Yipppeee!!! I soon found out that it only moves very slowly. Also when on level ground, it seems to cut out intermittently.

Now, I did replace the solenoid when I first started this sled ride, so that would be the other variable.

What do you think?
m

[JohnnieB]

Put the controller in diagnostic mode and maybe it'll beep a code.

Text at bottom of label tell you how.

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What did the connector with wires installed cost?

[mdavey]

One long beep, three short ones - Speed Sensor fault.

I rechecked my connections to the speed sensor on the DT04-3P plug. Looks like there might have been a lose crimp. These things are a bugger to crimp with a standard crimper. The crimper they sell is over $200!!!

I might just order the wiring harness and splice it back to the J5 Plug near the controller. The wiring harness was around the $30 range and the DT06-3S Plug Assembly was little over $5 plus shipping.

While I putz with this bugger, does it do any harm do drive it up and down our hill in crawl mode? I don't want to add to my things to do list by messing something new up lol.

[JohnnieB]

Twist the wires together, solder them and insulate the junction with a small wire nut.

Creeping around at low speed is hard on the motor and controller. Motor can draw very high current at low RPM, and that generates a lot of heat.

However, it might be too bad, since it is the controller that is limiting the amps going to the motor.

[yurtle]

They make wire nuts with some kind of silicon goo for use in wet environments, though I've only seen them used at 120 volts and higher. Might be overkill, but I was thinking they might help with corrosion.

[JohnnieB]

Vaseline works.

[yurtle]

On second thought, I wouldn't think it would be necessary unless it's in a coastal town, in which even all the crimped connectors would be prone to the same problem.

[mdavey]

Thanks Johnnie!