Alltrax Controller Overheating and Battery Voltage Issues

[Audipilot1]

Hello all, first post here.

I have a 2011 Club Car Precedent that has a jakes lift and 22" tires on it. I have slowly done some upgrades on. 2 years ago I upgraded the motor (I have the heavy case stock motor that I sent out to PQ to do the bandit upgrade), and at the same time installed a fresh set of Crown CR-190 batteries. The cart was getting about 24mph on the flat. Just this June I decided to upgrade the controller with the altrax 400amp XCT, and 2 gauge cables, new solenoid and user controller switch from Scotty at Carts Unlimited. The speed was, and still is amazing (31mph), however, my controller will overheat and shut down after running around for about 30 minutes. I've run multiple monitor files and Alltrax and Scotty concluded after a tweak to the Alltrax program that my battery voltage was dropping way to low driving amps up and therefore putting heat into the controller which caused it to shut down (was getting up to 90 degrees C). I added the accessory fan to see if that helped and after much discussion decided to go ahead and replace my batteries again with a fresh set of Trojan T-890 batteries (for a pretty penny I might add). I fully charged the new set and went for a ride this am to my dismay, the battery voltage on full charge was dropping and staying between 44-45 volts under load on the flat). I'm still getting 31 mph out of the motor but the volts arent right and the amps are high which is going to put the heat back into the controller. I have checked to make sure brakes arent grabbing and even flushed my differential fluid with the Purple SAE 5w-30. Alltrax and Scotty both have reviewed monitor files and settings (although I just sent them a new monitor file this am). I need to figure out what is going on with the cart as I cant keep overheating and shutting down (its leaving my wife and kids on the side of the road). Thanks for the help. I cant post the monitor files but am happy to share with anyone that asks for them (I get an invalid file type when trying to add them).

[Nutshell]

Heat is a product of resistance. Have you checked to make sure all your battery cables are 100%?

[Audipilot1]

Yup. As a matter of fact I had to remove them all yesterday to replace batteries and re torqued them. Motor connections and controller connections re done as well.

[scottyb]

Do you have access to a different motor you can try?

[Audipilot1]

Unfortunately I do not. That and the controller i would think are the only things left that could affect performance like this. But I’m still getting the speed out of the motor so I’m not sure that would happen if I was having a problem with it.

[scottyb]

Originally Posted by Audipilot1

Unfortunately I do not. That and the controller i would think are the only things left that could affect performance like this. But I’m still getting the speed out of the motor so I’m not sure that would happen if I was having a problem with it.

Alltrax came to the conclusion that trying a different motor would be a good diagnostic solution. A new monitor file with a different motor would be very helpful at this point.

[Audipilot1]

I’ll try and find a motor to try.