Controller super hot, cart shutting down

[lockman1]

IMO, the stock cable may be the reason stuff is getting hot,
Either an OBC by-pass cable or, an all-thread would be a good fix and the would be the first place I, personally would start!

[scottginfla]

Ok, thanks a lot everyone, I will do something with the OBC wire, one way or another and let yall know.
BTW, would brass have a low resistance?

[sonicj]

aluminum is the next best thing to copper. (well gold actually) but yea, brass is lower resistance than steel.

[gaminde]

yep gold but if you could afford the gold you could have one made from copper

[1fastbuggy]

I had the same problem yesterday i took the wife for a ride and she likes to go 20 instead of 40 like me so i was half throttle for about 4 or 5 miles and and my controller was hot and i believe it was about to go into thermal shutdown. I have an ezgo series cart on 48 volts 2 gauge welding cable, plum quick assassin, and 700 amp fsip controller. Once the cart cooled it was fine which seems the same as yours. As long as i am running it hard it doesnt heat up so i am wondering if it is the motor pulling alot of juice.

[rib33024]

What year are these batteries?? and how long did you let the pack rest before you took the pack reading, it needs to sit off the charger for 12 hours before you can get a true reading, this is how long you let them sit right??, and how did you load test the batteries/with what??

[scottyb]

fastbuggie, all these hopped up carts will build heat when you cruise at partial throttle for any length of time... just explain to the little woman that you need to cool the motor now and then and she better hang on now

[1fastbuggy]

HAHA Scotty ill try that next time.

[scottyb]

Blame it on me..... just don't give her my number!

[scottginfla]

Originally Posted by rib33024

What year are these batteries?? and how long did you let the pack rest before you took the pack reading, it needs to sit off the charger for 12 hours before you can get a true reading, this is how long you let them sit right??, and how did you load test the batteries/with what??

Feb 2010 trojan T875, yes, they had sat at least 12 hours.
They were load tested with a mechanical load tester with a digital volt meter hooked in.
The problem has been fixed, it was the stock cable running through the OBC that needed to be replaced with #2 welding cable to match the rest of the wiring on the cart.