Having trouble with over heating of the motor and controller needing tips

[moose80cj7]

I'm new to the cart world even though I have had my 07ezgo for a while. I have replaced my batteries and upgraded the cables. Now I was out on it today and it would just stop after riding along slow. The compartment where the controller is was very hot along with the cable going to the motor. I'm not looking for any kind of high speed. I'm planning on using my cart for hunting so I want as much torque as I can get for rough roads and hills. The cart was lifted when I purchased it and it has 14 inch wheels on it. I know I'm losing torque from them what should be my first try. I really don't have a lot of money to throw at it all at once so would it be better to start by upgrading the controller or the motor. I believe I figured out that I already have a 350 amp controller on it now. Sorry but y'all will have to be patient with me because all this stuff is way over my head.
Thanks for your all your help in advance.

[golfcartg]

Golf carts were made for cruising around the golf course on flat paved roads. They’re light, smooth rides that don’t require much torque or power to keep going. Now, throw in bigger heavier wheels and tires, a lifted frame, and the added weight of carrying gear or climbing hills, and you’ve changed the dynamics significantly.

The larger wheels give you more ground clearance which is great for rough trails, but they also increase the load on the motor and controller. This is because the larger wheels create more rolling resistance and require more power to turn. When you add soft ground or uphill riding into the mix, the system has to work even harder. As you push the pedal down and demand more torque, the motor tries to keep up, but it draws more current from the batteries.

The problem comes when that demand becomes too much for the controller. As the motor works harder to move the cart, the controller starts to heat up. The controller acts as the brain of the system, regulating power between the batteries and the motor. But when it gets too hot, it can trigger a thermal shutdown to protect itself which is likely why you experience it just stopping. Similarly the motor itself can get hot from the increased current draw which is why you’re noticing the cables to the motor heating up. Both the motor and controller are designed to handle the usual load of a stock golf cart like running on paved roads and carrying light loads. But they’re not built to sustain the heavy duty demands of off road hunting style use. Well, not without the proper upgrades.

The cables are another culprit here. Upgrading to larger cables is a good start, but those cables need to be sized correctly for the amperage draw of your motor and controller. If they’re too small or too long, they can increase resistance which creates more heat and reduces efficiency. The extra heat can cause all sorts of problems over time from damaged wires to thermal shutdowns.

As for what upgrades will help, the controller and motor are definitely where you want to focus. You mentioned that your cart currently has a 350 amp (probably stock) controller. That might be enough for lighter use on paved roads, but for off road, hill climbing, and carrying heavier loads, you’ll need more power. Upgrading to a programmable 400 or 500 amp controller would give you more headroom to provide the necessary power when the cart is under load. Make sure the new controller is compatible with your current setup and wiring and look for one that can handle the amperage you need without overheating.

Another thing to consider is the motor. You mentioned you have a stock motor, but depending on your needs, you might want to upgrade to a higher torque motor designed for off road use. One thing you might want to think about is whether you want to stick with a sepex motor or a series motor. Series motors generally offer more torque, which would benefit you for climbing hills and carrying heavier loads. On the other hand, sepex motors are more efficient and give you better speed on flat terrain. For your needs, I'd lean toward a series motor, as it's more suited for off roading and high torque situations like hunting. Just keep in mind that switching motors might involve swapping out the controller as well, so there’s some cost involved.

If budget is tight, you might also want to consider a gearing swap, going with a lower gear ratio can help the motor work less hard on hills giving you more torque without overheating the system. Just be aware that lowering the gear ratio could impact top speed, but that’s probably not a big issue if your focus is on torque for off roading.

Lastly, make sure your batteries are up to the task. If they’re older, they might not be able to provide the necessary current for your upgraded setup. Consider getting higher capacity or a lithium battery if you haven’t already. These types are designed to handle heavier loads and longer rides, which is exactly what you need for hunting. And if you’re unsure about making some of these upgrades, feel free to reach out or even considering a trade for a setup that’s designed for heavy duty use might be a good call.

Let me know if you need more specifics on any of the parts or setups