Hot solenoid

[Mark40]

Older non PDS TXT. M- to motor is hot. Solenoid is hot after driving 5 minutes.
Just put a rebuilt controller on it. How hot is OK and why?

[scottyb]

About 120º is okay on cable ends. That's hot but it won't do damage.
120º or 20º above ambient is all I expect on a solenoid after 10+ minutes

[Mark40]

OK, they are almost too hot to touch. Cable on left side of solenoid has gotten very hot in past. Strands seperated etc. same for M- cable to motor at controller end. Would this cause this or motor pulling to much amperage.

[JohnnieB]

The solenoid will warm up some because there is current flow through its coil when energized. Nearly too hot to touch, sounds a bit on the too warm side.

Any cable that shows any evidence of overheating, needs to be replaced. In fact, if it is an older cart, chances are high that the cables are 6Ga and they all (13 of them) ought to be replaced with 4Ga or thicker.

Any heat in any of the high current cables is lost electrical energy that should be going to the motor, so the cart is not performing as well as it could be with good cables.

It is normal for the motor to get hot since amps not converted into torque are converted to heat. Max recommended motor case temperature is 239°F, which is above the boiling point of water and far too hot to touch.

The controller will warm up a bit also, but like the solenoid, it shouldn't get too hot to hold onto for several seconds.

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If you are running tall tires, the motor will draw more amps and things will warm up more. The amp deliver system may need to be upgraded to match the load being placed on motor.

[Mark40]

Thanks guys!