36v EZGO just clicks when pedal is pushed

[rotus623]

Ok guys, thanks for all the continued support. I just got back at it as other things had taken priority.

Anyways I have visually inspected the controller, and it looks great. All connections and connectors look perfect. Wiring is all in good shape.

Pulled the motor and the first thing I noticed was it smelled like burnt electrical. It is an unmistakable smell that I have smelled after burning up electrical components. If I spin the motor by hand it will make noise if it hits a magnet, but otherwise I cant really hear anything.

I pushed the cart without the motor installed and it felt smooth and did not make a grinding noise. Is there anyway to test the motor before I break it down to inspect further? I would like to be completely sure that this motor is toast before I replace it.

Would a stuck closed solenoid cause a motor to overheat? I think after hitting the switch a few times I got continuity on the main posts on the solenoid with the pedal DOWN, but it was intermittent.......I am trying to figure out what would have done this. Remember that the last set of batteries that were in this thing were all expanded so they were either running hot or overcharged..........

[BobBoyce]

Originally Posted by rotus623

Remember that the last set of batteries that were in this thing were all expanded so they were either running hot or overcharged..........

Likely expanded from sulphation. When lead/acid batteries are left in a partially or totally discharged state, lead sulphate crystals begin to grow between the plates. The lower the state of charge, the faster the crystals grow, until the sulphur of the sulphuric acid is all consumed. As these crystals grow, they push the plates apart, swelling the cells.

Bob

[rotus623]

Gotcha. Any ideas why the motor smells burnt? Any simple tests to verify this?

[BobBoyce]

Originally Posted by rotus623

Gotcha. Any ideas why the motor smells burnt? Any simple tests to verify this?

A number of things can burn the windings in a motor. The most common is running the motor too slow while heavilly loaded. Putting on too big tires/wheels can do that, as it alters the effective gear ratio. Slows the motor speed while increasing the load on the motor. Too much current through a motor will overheat it.

Essentially, check continuity on the Field (stator) and Armature windings, and check for shorts between any terminal and the motor case. If that checks out, jack up the cart and get the rear wheels off of the ground. Then use a 12V battery to apply power to the Field windings and Armature windings at the same time and see if the motor runs. The motor needs to stay mounted to the rear axle while you do this.

[rotus623]

Originally Posted by BobBoyce

A number of things can burn the windings in a motor. The most common is running the motor too slow while heavilly loaded. Putting on too big tires/wheels can do that, as it alters the effective gear ratio. Slows the motor speed while increasing the load on the motor. Too much current through a motor will overheat it.

Ok, thats good to know. The cart is raised with bigger wheels and tires.
Is there any other way I can verify motor failure instead of just going by the smell of it? Hard to tell if the annealled wire is shorted via visual inspection.

If I recall correctly, I put my test leads on the main + and - wires (A1 and A2) and when I pressed the pedal down I got 38v at the terminals. This would suggest that the motor was getting its signal voltage, no?

[rotus623]

So I want to bench test the motor.

I have A1, A2, S1 and S2. It is a 36v motor.

I heard that I have to jump s1 to a2, then positive battery wire to s2, negative battery wire to a1. Does that sound right?

[JohnnieB]

Here is how to test a series motor.

It has to be mounted on the differential since there is no front bearing to support the armature and it will be damaged if not supported.

[rotus623]

Thanks johnny you are the man!!!

[ilflyer]

Watching, have same problem with mine.

[rotus623]

Originally Posted by ilflyer

Watching, have same problem with mine.

What code are you getting? High pedal?