1993 Club Car DS Upgrade Now Motor is Overheating

TMeachum

Member
I have a 1993 Club Car DS. I upgraded to a Navitas series 440amp controller and speed motor. Now within minutes of run time the controller shows error code that the motor is overheating. I checked the voltage at the batt and the controller for voltage drop and have none. Any ideas what to look for now?
 

Tom47

Cartaholic
What voltage is your cart, 36 volts or has it been upgraded to 48 volts? What is your full charge voltage 12 or more hours after the charger shuts off?
 

Tom47

Cartaholic
Your pack is not performing well. It should not drop below 35 volts pulling away from a stop and also should not level out at less than 36 volts.

Hook up your VOM across each battery and try the same maneuver. See if you have one that is dropping more than the others and affecting your pack voltage.

What is the date code on the batteries?
 

Diode

Cartaholic - V.I.P. Sponsor
What motor are you running if you don't have an AC system then turn off the motor temperature sensor in the controller
 

TMeachum

Member
The Navitas installation/service manual that came with the controller said it is compatible with clubcar DS WITH CURTIS 1510/1515 also the 1520 and 1268 (resistive throttle). My controller was a Curtis PMC 1204-015. I’m not sure if it is the correct one and the wiring diagram is showing a run tow switch and mine does not have one. It also said in the manual that it must use a diode but the techs at Buggies unlimited told me to take it off That it didn’t need it.
 

TMeachum

Member
I have rewired the entire cart.
 

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Diode

Cartaholic - V.I.P. Sponsor
If that controller is only good for the 1510 and the 1515 controllers then it is an IQ controller only, you are running a series motor you either need to run a sepex motor or a series controller.
 
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