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Electric Club Car Electric DS, and Precedent golf cars |
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12-01-2015, 09:00 PM | #1 |
Not Yet Wild
Join Date: Dec 2015
Posts: 9
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'02 DS fully charged, shudders, slow, & hot cables
Newbie here. We've recently developed an issue with our 2002 48V DS. The battery pack shows 51 volts but it shudders when accelerating and is quite slow. Step-daughter had been driving it and the orange cable from the forward/reverse switch was overheated.
I did some searching here and found this threads that seem to be relevant. Will be following the suggestions in the threads but thought I'd post here for support :-) buggiesgonewild.com/electric-club-car/85465-2003-club-car-ds-runs-then-slows-crawl.html buggiesgonewild.com/electric-club-car/92486-1999-ds-cart-wont-move.html buggiesgonewild.com/electric-club-car/112836-2005-cc-ds-shuddered-now-slower-driving-slow-charge-jerky-speed.html buggiesgonewild.com/electric-club-car/111970-did-i-fry-new-controller.html buggiesgonewild.com/electric-club-car/24070-resetting-obc.html |
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12-01-2015, 09:14 PM | #2 |
Old Sky Soldier
Join Date: Dec 2011
Location: Kentucky
Posts: 3,881
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Re: '02 DS fully charged, shudders, slow, & hot cables
Anytime a cable overheats, there is a problem. Most likely need to replace that cable. Make sure all cables have good clean tight connections.
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12-05-2015, 06:40 PM | #3 |
Not Yet Wild
Join Date: Dec 2015
Posts: 9
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Re: '02 DS fully charged, shudders, slow, & hot cables
Ok. Here's an update on what I've discovered so far:
Cable connections were all secure. Also, I should mention step-daughter had her boyfriend tow the cart a few days before these issues started. Battery pack total voltage: 50.3 volts All but one battery showed 8.4 volts, the other showed 8.3 volts. I used an electrolyte tester that used 4 floating balls to test each cell. All cells floated all four balls except for one cell on the low voltage battery. 3 floated and one was halfway sinking. Batteries are from 2012. Measured resistance from the controller for the accelerator (green and yellow wires to the controller.) Initially reading was OL (open circuit). Even after I heard the solenoid click I still was seeing OL. Eventually, I was getting a highest reading of about 4300 and a low reading with the pedal all the way down of about 1055. Voltage input on the controller was the same as the battery pack voltage. Voltage output on the controller never got above 11 volts. To those who know, any recommendations? |
12-05-2015, 07:10 PM | #4 |
Happy Carting
Join Date: Dec 2007
Location: Southern California
Posts: 73,418
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Re: '02 DS fully charged, shudders, slow, & hot cables
Like you have a battery cell dropping out under load. Put the meter on the 8.3 battery and see what the voltage for this battery drops to under load.... preferably uphill.
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12-05-2015, 07:12 PM | #5 | |
Old Sky Soldier
Join Date: Dec 2011
Location: Kentucky
Posts: 3,881
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Re: '02 DS fully charged, shudders, slow, & hot cables
Quote:
Towing cart without putting run,tow switch in tow will kill the controller dead.. |
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12-05-2015, 09:37 PM | #6 |
Not Yet Wild
Join Date: Dec 2015
Posts: 9
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Re: '02 DS fully charged, shudders, slow, & hot cables
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12-06-2015, 03:50 AM | #7 |
Old Sky Soldier
Join Date: Dec 2011
Location: Kentucky
Posts: 3,881
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Re: '02 DS fully charged, shudders, slow, & hot cables
I was thinking it was regen. You need to load test the batteries like scoyyb said, then report what you find.
These guys need this information to tell which step you need to take next. Anytime a cable gets hot and is the only one that is a bad cable or bad connection. |
12-06-2015, 08:41 AM | #8 | |
Not Yet Wild
Join Date: Dec 2015
Posts: 9
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Re: '02 DS fully charged, shudders, slow, & hot cables
Quote:
Would it make sense that if the controller isn't outputting full voltage that excessive amps are being drawn to make up the difference causing the cables to overheat? |
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12-06-2015, 08:53 AM | #9 |
Not Yet Wild
Join Date: Dec 2015
Posts: 9
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Re: '02 DS fully charged, shudders, slow, & hot cables
Should the accelerator drop lower than 1055 Ohms at full throttle? Or is that a good reading for full throttle?
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12-06-2015, 05:45 PM | #10 |
Not Yet Wild
Join Date: Dec 2015
Posts: 9
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Re: '02 DS fully charged, shudders, slow, & hot cables
I spent a little more time today searching for loose cable connections. Nothing. They all are tight & secure. The motor seems to run quite hot. I'll have to shoot it with my temp gun from work tomorrow.
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