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Unread 09-14-2015, 08:39 AM   #1
Not Yet Wild
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Default Batteries and/or something else?

I am a new first time owner of a 2003 Club Car DS, 48V with IQ. When I bought the cart, the former owner indicated the batteries (Energizer GC8,s Sams Club) were fairly old but still good; I cannot find any type of date code on them to verify age. When I test drove the cart, it did fine on hills, etc., and all seemed great; only issue I noticed was the backup/roll-away alarm was flaky and inconsistent. Got it home and checked water in batteries; it was low below the plates in several cells. Brought level up above plates and charged, and it seemed fine for a few days.

However, after a couple of charges, it started behaving erratically; very slow going up hills and even level ground, but going down the regen system works where it is supposed to both pedal up and pedal down, so I assume speed sensor is fine...

The charge time also went up dramatically; first couple of charges took 6-8 hours for charger to shut off, but now it takes 30-45, and you can hear the batteries bubbling/boiling during charge and for hours after charge is complete and charger is removed.

Long story short, I suspect the batteries need replaced, but I am wondering if that is likely to be all; I have been told that weak batteries tend to limit range long before they noticeably effect speed/torque, which did not seem to happen (I drove it 10-12 miles on each of the first two charges), and I have also heard that the charger is supposed to shut off within 16 hours even if the cart is not charged, and not kick back in to refresh for around 15 days; when I left it plugged in for few days, it initially charged for 42 hours, then kicked back on in under 24 hours... Charger is a PowerDrive II.

I just hate to drop $900+ on batteries if that is not likely to be the only problem...
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Unread 09-14-2015, 11:09 AM   #2
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Default Re: Batteries and/or something else?

Well , what kind of voltage do they have ? cant tell much until you get a voltmeter on there...
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Unread 09-14-2015, 11:16 AM   #3
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Default Re: Batteries and/or something else?

Pack at rest reads 53V, and individual batteries show 8.2 - 8.3. Under load the pack voltage drops momentarily to 36-39 V and then settles out around 42-43V.

I am fairly sure the batteries are weak and need to be replaced, but am wondering if there are likely to be any other issues.

One other detail is that when it is running extremely slowly up a slight incline, occasionally it will surge and run like it should for 100 feet or so and then slow down again, and occasionally stopping and restarting will make it run up to speed briefly. The inconsistent nature is what has me most confused...
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Unread 09-14-2015, 11:55 AM   #4
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Default Re: Batteries and/or something else?

Yeah , that's really low...even under load should stay above 45 to 46 I think uphill.....could be just one dropping out on you but still time to bite the bullet....connections and cables could cause surge , along with the low voltage I think...
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Unread 09-14-2015, 12:03 PM   #5
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Default Re: Batteries and/or something else?

Do the same load test on each battery. I'm guessing you'll find one that isn't doing it's share.


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Unread 09-14-2015, 12:13 PM   #6
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Default Re: Batteries and/or something else?

AND, if it turns out batteries are required, $900 for a set is outrageous for the Atlanta area. Shop around. On the south side premium brands such as Trojan are more like $6-700.
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Unread 09-14-2015, 12:27 PM   #7
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Default Re: Batteries and/or something else?

Quote:
and I have also heard that the charger is supposed to shut off within 16 hours even if the cart is not charged, and not kick back in to refresh for around 15 days;
You heard correctly.

You need to get your charging system working properly before you put new batteries in the cart.

With the charger AC cord unplugged, spray WD40 on the charger receptacle and work the DC plug in and out a few times to clean any corrosion.

Make sure the fuse on the sense wire (gray) is making good connection and the OBC/charger receptacle has not been modified in any manner.

Also make sure there is only 1 cable on the pack negative and it passes through the OBC on the way to the controller B-
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Unread 09-14-2015, 12:43 PM   #8
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Default Re: Batteries and/or something else?

Quote:
Originally Posted by Sergio View Post
Also make sure there is only 1 cable on the pack negative and it passes through the OBC on the way to the controller B-
There is also a wire going to a voltage reducer which powers the lights; is this an issue?
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Unread 09-14-2015, 12:46 PM   #9
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Default Re: Batteries and/or something else?

Quote:
Originally Posted by kernal View Post
AND, if it turns out batteries are required, $900 for a set is outrageous for the Atlanta area. Shop around. On the south side premium brands such as Trojan are more like $6-700.
Can you recommend a search term I might use to find such a vendor? In E/SE suburbs, I have found three who carry Trojan and all want $150 ea. Even Sam's Duracells are $99 each...

I would prefer crown if they are available locally...
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Unread 09-14-2015, 01:00 PM   #10
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Default Re: Batteries and/or something else?

Quote:
Originally Posted by JDFester View Post
Can you recommend a search term I might use to find such a vendor? In E/SE suburbs, I have found three who carry Trojan and all want $150 ea. Even Sam's Duracells are $99 each...

I would prefer crown if they are available locally...
If you want to drive to Augusta, we can blow that price away, and sell you a new Onboard computer as well to address your charging issues. It shouldn't charge that long. There's obviously something wrong with the OBC. It should shut off way before the duration that you described.
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