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Unread 12-26-2015, 06:58 PM   #1
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Default 2002 48v Club Car IQ slows then stops

We just picked up a nice 2002 club car IQ 48v a couple of weeks ago. It's got new batteries in it but its had a little issue a couple of times now. After driving it around for a bit, probably 30+ min at maybe 5-8 mph with a couple of passengers the forward movement will start to slow and then basically stop. I can usually switch to reverse and it's fine but going back into fwd it will barely move. The last time it happened today reverse would also no move. The three times it happened I let it sit for just a short time (maybe 2-3 mins) and then it went fwd just fine. They motor is warm but no so much that you can't touch it and leave your hand there for at least 10-15 seconds before it gets uncomfortable. I did notice that a part of the frame in the back of the battery compartment was pretty warm as well. I'm assuming that the regulator (or something like that) is mounted to the back side of the frame there and is a heat sink for said component. So any idea what might be going on? What can I check. I'm new to carts but am very adept with electronics.

Thanks in advance
Dan
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Unread 12-26-2015, 07:31 PM   #2
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Default Re: 2002 48v Club Car IQ slows then stops

What is the battery pack voltage when it stops.? Welcome to BGW
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Unread 12-26-2015, 08:01 PM   #3
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Default Re: 2002 48v Club Car IQ slows then stops

Sounds like the controller going into thermal cutback. Is the cart lifted or has bigger tires / wheels?
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Unread 12-26-2015, 08:49 PM   #4
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Default Re: 2002 48v Club Car IQ slows then stops

Haven't checked the battery voltage (i will) but the charge indicator is still basically topped out.

The cart is indeed lifted with larger tires.
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Unread 12-26-2015, 08:55 PM   #5
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Default Re: 2002 48v Club Car IQ slows then stops

So let me guess, the guy who built it didn't account for the tires and lift so I've got to upgrade the controller?

How would I verify that it is indeed the controller overheating?

Anything else I should take a look at?
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Unread 12-27-2015, 12:41 AM   #6
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Default Re: 2002 48v Club Car IQ slows then stops

Take off the small access panel underneath the sweater basket as well as the environmental controller cover. Next time the cart dies, place your hand on the controller and feel if it is hot
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Unread 12-27-2015, 10:36 AM   #7
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Default Re: 2002 48v Club Car IQ slows then stops

Thanks, I will try that today. I can tell you that the frame on the back side of the controller (now that I know what that is) gets hot. I'm assuming they use frame as part of the heat dissipation system for the controller.

For just a minute let's assume it's the controller and I need to replace it. (1) how big do I need to go (400A, 500A?... Decent brands?) And (2) will the stock motor burn out with the higher current?
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Unread 12-27-2015, 10:39 AM   #8
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Default Re: 2002 48v Club Car IQ slows then stops

Also, will I need to upgrade the solenoid and the wiring to accommodate the increased amperage?
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Unread 12-27-2015, 10:40 AM   #9
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Default Re: 2002 48v Club Car IQ slows then stops

The "latest and greatest" controller right now is the Alltrax XCT. Many new features makes it one of the best on the market right now. The 400a XCT does also work with your stock motor
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Unread 12-27-2015, 11:17 AM   #10
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Default Re: 2002 48v Club Car IQ slows then stops

AQ0327-

Stock motor and controller, new T-875's runs 19 MPH with regen limiting it at WOT,...


no heat problems,...
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