96 EZGO Motor Cables Getting Hot

[davidkozak1]

Golf cart will run if I push it to get it to move. once moving it will take off and run great. But to get it to move the motor and cables get so hot you can't touch it. And the heat moves to solenoid and controller. Motor was replaced, new 4 gauge cables. solenoid replaced. Controller tested good from Flight systems. Batteries are testing good. Just has no take off power.

 

[Notsoslim]

23" tall tires?

 

[davidkozak1]

No standard golf cart tires.

 

[Golf Cart Wizard]

Where did you get the motor from and what model?

 

[davidkozak1]

I'd have to look at it. the customer put the motor in it thinking it was the problem. I have a good use motor so I pulled his out and put my motor in. same problem.

 

[Golf Cart Wizard]

Is this a DCS or series cart?

 

[davidkozak1]

yes

 

[Golf Cart Wizard]

Is this a DCS or series cart?

 

[davidkozak1]

DCS

 

[Jeff104]

DCS

have you load tested the batteries ?
weak batteries cannot maintain their voltage under heavy loads
lower voltage on the motor means greater amps to do the job
more load on the battery causes lower voltage
even more amps
even less voltage
you see where this is going ?

 

[davidkozak1]

I've done that too. I ran a discharge test on them. all in range. They go down to 5.8 give or take and all even. At full charge same thing. No take off power.