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Unread 06-23-2015, 12:50 AM   #1
Not Yet Wild
 
Join Date: Jun 2015
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Default Problems with extended slow speed operation

Hello all,

I have an electric Club Car cart that I purchased used (and lifted) about eight years ago. Part of the deal included a set of new Powertron batteries. I had a new set of Interstate batteries installed with new cables two months ago. No big failure led to the batteries R&R but loaded voltage tests and shortened run times helped make that decision (and they were old). The cart's serial number begins with AQ0318, so I reckon it's a DS IQ, 48 volt regenerative model... I've been doing some reading on your fine forum. I also think that s/n prefix tells us it's a 2003?

Before the recent new batteries went in, AND after the set installation I have experienced trouble that shows up after lots of slow speed operation. It's the only time I have any issues. I can run high speed all I want, with starts always normal. Something is getting hot I suspect when I creep along for long periods. I have two different tasks for my cart that require lots of slow speed operation; otherwise I'd not worry too much about it. The trouble that appears is a no-go condition. It acts like depleted batteries. Ten minutes later I can drive off OK if I avoid the slow speed stuff. The cart is put to bed on-charge on days of use. The system is stock as far as I know and the charger is a stock OEM I think.

All suggestions, leads, tips and stories will be greatly appreciated.

Thanks!
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Unread 06-23-2015, 07:06 AM   #2
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Default Re: Problems with extended slow speed operation

This sounds to me like your controller is getting hot and shutting the cart down, usually you can put your hand on the controller and feel a huge amount of heat coming off of it when this occurs. I see this a lot at my dealership when people use carts to put sprayers on the back and drive at extremely slow speeds for a while.
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Unread 06-23-2015, 12:14 PM   #3
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Default Re: Problems with extended slow speed operation

Quote:
Originally Posted by camaroluvz28 View Post
This sounds to me like your controller is getting hot and shutting the cart down, usually you can put your hand on the controller and feel a huge amount of heat coming off of it when this occurs. I see this a lot at my dealership when people use carts to put sprayers on the back and drive at extremely slow speeds for a while.
First, thanks Camaroluvz for your reply...

I first encountered this problem when blowing leaves from my cart... I fabricated a mount for my big backpack blower so I could still get use from it after I acquired a FULL Lifetime Membership in the Bad Back Club. The setup works very well but, like those folks with their spray rigs, it does involve long periods of slow speeds. I have now faced this problem most recently at night when armadillo hunting. Same M.O. Slow going.

In diagnosing this I understand that anything I do may be a hip-shot at a fix. In going forward I need to ask which component is the "controller" .... is it the electrical part of the electro-mechanical arrangement that the foot control actuates or is it further downsteam?

Thanks...
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Unread 06-23-2015, 12:35 PM   #4
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Default Re: Problems with extended slow speed operation

The speed controller, Its located behind the motor cover on the rear of the cart. The plastic cover thats held in place by two phillips screws above the bagwell on back of cart. After removing that, you will see the controller hanging upside down toward the pax side I believe on your cart. its a rectangular box with three or four large wires and a bunch of smaller ones going to it.
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Unread 06-23-2015, 12:42 PM   #5
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Default Re: Problems with extended slow speed operation

Camaroluvz28.... thanks again....
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Unread 06-23-2015, 12:52 PM   #6
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Default Re: Problems with extended slow speed operation

Any time...let us know what you discover. The best part about this forum is people with similar problems can read up on how you fixed yours and hopefully get some help themselves. ;)
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Unread 06-23-2015, 09:40 PM   #7
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Default Re: Problems with extended slow speed operation

Roger that.

All I have done to her today is to brace a light bar I installed yesterday that had way too much shakin' goin' on... sorry Elvis.

I did locate the controller per your suggestions and now know what to inspect next time I make the issue develop.

P.S. the light bar, when finished (read, wired), will give me the light I need to see all the armadillos, all the time. In addition to the OEM headlamps the light bar has three sets of driving lights mounted on it. After many years of motorcycling I found a few spare sets of lights! I will wire them through a common relay with an independent switch on the dash.
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Unread 06-23-2015, 09:56 PM   #8
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Default Re: Problems with extended slow speed operation

Quote:
Originally Posted by camaroluvz28 View Post
The speed controller, Its located behind the motor cover on the rear of the cart. The plastic cover thats held in place by two phillips screws above the bagwell on back of cart. After removing that, you will see the controller hanging upside down toward the pax side I believe on your cart. its a rectangular box with three or four large wires and a bunch of smaller ones going to it.
Close, but no cigar. He has an IQ, so under that access panel, the controller will be mounted straight up and down on a flat aluminum panel right under the access panel. It will be a black rectangular box
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Unread 06-23-2015, 10:12 PM   #9
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Default Re: Problems with extended slow speed operation

Yepper.

What I found from the bottom-on-a-creeper tonight was mounted on an aluminum plate/bulkhead; dark color; the size was about 11" x 8" x 2" and there were multiple big gauge wires and multiple lesser gauge wires plunging into the box with no external connections at all.

I intend to "feel it" so as to report on its felt temperature when doing the slow speed thing. Too hot to touch will be the cut-off I reckon.

Are these controllers rebuildable? I spent the last 35 years repairing electro-mechanical things and have no fear with regard to "opening the box"

Thanks.
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Unread 06-23-2015, 10:24 PM   #10
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Default Re: Problems with extended slow speed operation

Quote:
Originally Posted by ClubCarCooter View Post
Yepper.

What I found from the bottom-on-a-creeper tonight was mounted on an aluminum plate/bulkhead; dark color; the size was about 11" x 8" x 2" and there were multiple big gauge wires and multiple lesser gauge wires plunging into the box with no external connections at all.

I intend to "feel it" so as to report on its felt temperature when doing the slow speed thing. Too hot to touch will be the cut-off I reckon.

Are these controllers rebuildable? I spent the last 35 years repairing electro-mechanical things and have no fear with regard to "opening the box"

Thanks.
They are repairable. Most repaired controls last 6 months and can be repair as many times as you have money to do so. Repair is less expensive than buying a new or aftermarket control with higher capacity and increased durability until about the 2nd or third time you repair it - at that point you could have had upgraded performance and durability. The new XCT control from Alltrax offers a cooling fan for high heat dissipation.
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