Hello and HELP! ...lol

C

Capt. Kirk

Member
Hello, new here but have been reading a lot of good stuff for a couple of months.
2015 Club Car Presedent 48V
Bought it about a month ago and put in fresh Trojans which really helped performance, also upgraded to 4ga. cables which stay nice and cool.
One evening the wife and I (and our dog) went for a cruise around the area with our neighbors on their cart. Up until this point all was good.
After about 6 miles I got the surging at the pedal and limped back to the house at about 10mph. Everything I read on the net pointed to the MCOR so I replaced it with one off Amazon (yes Chinese) as there were mixed results about how long they last. (Some say years, some say months, some say weeks) After I replaced it the cart seemed to run fine, we took the same trip (even a few more miles) and it ran like new.
Tonight we went again and went a little further and it started the same thing. Once again limped home. The MCOR has only been used a few trips. When I got back home I let it sit for a while thinking maybe it was due to the motor getting hot, went back out after about 20 minutes and tried it just up the street. Same surging.
Reached under it and put my hand on the motor and it was hot but no smell or anything but after about ten seconds you would have to remove your hand.
Could this be the brushes needing replacing? Or bad MCOR? Or speed sensor (I didn't replace it when I replaced the MCOR)
Side note: When I replaced the MCOR I took my Dremel tool and cut open the old one out of curiosity and could see no burned contacts and the micro switch worked good)
Thinking of getting the good MCOR (I will have to look up the company again) and get a new speed sensor this time. But I am wondering if I should replace the brushes on the motor also?
Sorry to be long winded, wifey is getting a little tired of this happening.
Thanks in advance.
 
They are on charge now. If in the morning it runs normal could it be motor brushes? If it does run normal tomorrow then how could it be the MCOR? I suspect it is something getting hot (motor or controller??) The outside temps were around 85 degrees.
 
One other thing I noticed when limping home, the voltage would be around the 48.5V to 49V range and once in a while blink down to 43V then back up. Don't know if that could be 1 battery going bad or not, they are brand new Trojans.
 
So I go out after it has charged for 3 hours and it shows full charge. I turn it on and take it out, up and down street and it is back to normal, smooth and loads of power, hits 23-24mph with no sweat. Now I'm starting to think after a long ride, the motor warms up and maybe worn brushes cause the surging until everything cools off. What do you think?
 
I doubt it I would say it's a battery or big wire problem possibly controller getting warm.
 
Last night I did feel the controller when I turned off the cart and it did feel warm, but how could you keep it cool? Also how could I check each battery to find which of the 6 is the culprit if that is it? Why would it only do it after a long ride?
 
The longer you drive the lower the batteries get. You have lead not lithium, voltage drops as they discharge. Do you have your accessories ran across all 6 batteries or just off 2? When it starts surging measure each battery voltage individually and if none show significant difference you will have to accelerate while testing each individual battery and see what the voltage drops to when you hit the pedal
 
Right now the lights run off 2 batteries but I have a 48v to 12v converter on the way so that will take care of that. Yes I will check each battery that way. Now that I think about it it only happened after a long ride and with the lights on. I am also going to change the old headlights to LED that may help a little but I suspect like you say if the accesories are now run off 2 batteries, when the voltage gets low then those two could be dipping down enough to cause this. Does that make sense? lol
 
If you’re running halogen lamps off of two batteries riding at night then yeah that’s your problem. You’re drawing the two batteries so low it’s triggering the low voltage cutoff in the controller causing the surging.
 
Well since it runs fine when cold I will have to wait for it to start surging again. Then I can perform the test. I only saw it do the 43V a couple of times when limping home. It was just a blip then back to normal wouldn't the motor surging cause a momentary dip? Anyway I will get more results after testing batteries. Even if I have to disconnect them and do a load test on each.
 
Just raise cart and run in forward, check each. Got it, thanks.
Oh one more thing, is this the way Club Car designed the lighting circuit on all their carts, using leads to 2 batteries on the 48V system??
If so why didn't they put a converter on?
 
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