Club Cart stops running

[Den59]

I have a 97 Club Car DS, I replaced the motor controller, solenoid, F/R switch. Today I was driving the cart came to a stop, and then it would not move. After a while sitting there then it would start moving. About an hour went out again and it did the same thing. I checked the wires everything is tight, the solenoid click but no peddle response again after sitting about 10 min it starting moving. Any thoughts on what to check?

[Den59]

Also have all new batteries

[jjance]

Are the batteries charged and up to the water fill level.

[Den59]

Batteries have a full charge and water is good

[jjance]

Maybe the controller is overheating and going into thermal overload. After you drive for a while feel the motor and controller and see if it is getting too hot. Five second rule. If you can hold your hand on it for a 5 sec count it's not to hot. What was the time interval between changing the controller and your problems starting?

[Den59]

The new motor and contoller have been on 5 to 6 months

[klanel]

I would also be leaning towards the controller and a thermal problem. Purchase a can of freeze spray and when it stops, spray the components and the circuit board on the controller and see if it starts working again. If so, likely that either a component is overheating or you have a bad connection on the circuit board. I'd first look for cold solder joints, especially around larger structures or places that could be mechanically stressed. Look closely and if you see a ring around where the component lead is soldered, it needs resoldering. Also look for cracks in the foil traces which are possible but less likely. Do this is if you can get the cover off. Since I'm not familiar with the controller construction, don't know if this is an option. The freeze spray you can get from an electronic supply house. Mcm electronics, Newark electronics, to name a couple. If not a bad connection, I'd be leaning toward a component overheating as mentioned by jlance. Good luck.

PS: the freeze spray is non conducive and safe to use on powered electronic equipment. So no need to power down.

[jjance]

Only one thing to add about Klanel's response. If there is any possibility that your controller is still under warranty don't take it apart. Send it in for repair. Just thought of something else. What kind of motor and controller do you have?

[Den59]

It's a brand new alltrax controller. I can't remember the make of the motor it's 6 hp I bought from buggies unlimited . I bought a heat sink and a fan I am going to mount on it to see if that works. It's about a year old, but I built a 57 Chevy cart and I don't think enough air is getting up there? I hope the heat sink and fan does the trick?

[Muddog]

Why did you buy the fan and heatsink ? Was controller too hot to touch after shutdown?