lifted club cars - lifted ezgo
Home FAQDonate Who's Online
Go Back   Buggies Gone Wild Golf Cart Forum > Golf Cart Repair and Troubleshooting > Electric Club Car
Electric Club Car Electric DS, and Precedent golf cars



Post New Thread  Reply
 
Thread Tools Display Modes
Old 10-29-2017, 11:25 PM   #1
CallMeColt
Not Yet Wild
 
Join Date: Oct 2017
Posts: 9
Default 2011 XRT 800E Refurbishing Thread

Everyone,

As the title says, I'm starting this thread do document my refurbishing of a neglected 2011 XRT 800E cart. I will try to be as descriptive as I can to help any others that may need help with this model cart as I'm coming up with not a lot of anything via hours of the Google.


This is our first golf cart. We recently moved onto a small farm & wanted something for getting around the property & neighborhood. It also makes chores much easier. This model has the small utility bed on it.

We got the cart for $1,200. It last ran in January 2016. As I type this it's the end of October 2017. Had some front end damage due to an older ranch hand hitting a tree with it. The keys were missing. one small wire was cut under the seat. The batteries were originals & looked rough. Overall though, the cart was in decent shape... just looked neglected.


After getting home, the first thing I did was check the batteries. All were between 0 & 2 volts. Hooked the charger up to see what it would do & nothing. After looking at everything for a while, I figured the wire that was cut went to the same battery lug as the positive to the motor. This wire comes from the charging port. Still got nothing. Knew at this point I needed new batteries.

Since it was to late to go buy batteries, I spent some time removing the starter key switch & replacing it with a toggle switch. I have no worries of theft where I am.


Today I went to Sam's Club & got 6 new Duracell GC2 batteries. Cleaned up the wires & replaced any bad or missing cable ends. Hooked the batteries up as they were supposed too. Checked water. I got a reading of about 37 volts total. This had me worried at the time (before I found this forum) but after reading the batteries stick thread, it's normal for new batteries to be a 75% charge.


I did get power on the dash when I moved the switch under the seat back to run. Moved the toggle switch to on & tried to move the cart in reverse... got the buzz but no movement. At this point I noticed the battery gauge went from full to about 1/3. Found that odd. Plugged in the charger & it started charging but the amp reading pegged up over 15. This had me really worried but after a little bit, it did come down but was still over the 15 line. I just let it go since I knew the batteries were at 37 volts.


After coming inside for my initial Google search & looking some things up, I went back out & pulled the charger off. Tinkered a bit more checking wires & stuff. I hit the reverse switch & pressed the pedal... started moving. The toggle was in the off position. Really had me confused but I came to the conclusion that the starter switch works off a break in a circuit instead of closing one to complete it. No matter what position the toggle is in, the batter gauge stays lit. Not sure of this is normal? I'd think this would train the battery.At this point it is at 0% where it has the last two bars alternate quickly.


I buttoned everything back up that I had apart & took a drive up & down the road. The battery gauge still at 0%. I wanted to make sure it drove okay. Since then, I've had it on the charger. I pulled the charger off to check voltage a few times. 42 volts after 4 hours. I noticed the batteries are making a bubbling sound & have a light odor of sulfur (rotten eggs). The charger is still at the same place a little above 15 amps. Google search gives me answer from your battery is going to explode to mine always makes bubble noises when charging. They're not hot even after 4+ hours of charging. Pictures from my thermal camera show ~80degF. It's a cold south Texas night & is 54degF. I will share those pictures in a separate post at my limit of 5 has already been reached for this post.

The amber battery light was illuminated when on & not moving. After searching a bit, this means it's below 90% charge. It did have me a bit baffled however that when it was switched off, it would come on & off... but in 15-20 second intervals. Nothing about this in the book. There is a 10 second on, 4 off that means charge issue or 25% charge but it's not even close to that.

I'm going to try & attach pictures to go along with this. UPDATE apparently I can put them in the post because I'm to new. Will update later if I can.

Here are my questions;

1 - Am I going to mess anything up with the charger showing over 15 amps?
2 - Could me installing a toggle instead of a new key switch be causing any issues? Like the reverse buzzer still sounding even when the switch is off not letting the cart move. Or the battery gauge always on.
3 - Has anyone else heard their batteries bubble while charging?
4 - Would anyone be able to tell me if I put the two smaller wires in the correct places on the batteries? I wasn't able to find a diagram in the thread with them for my cart.


Any other pointers would be great.
Attached Images
File Type: jpg IMG_20171029_230317.jpg (211.2 KB, 0 views)
File Type: jpg IMG_20171029_230326.jpg (217.9 KB, 0 views)
File Type: jpg IMG_20171029_230331.jpg (225.7 KB, 0 views)
File Type: jpg IMG_20171028_083440.jpg (217.0 KB, 0 views)
File Type: jpg IMG_20171029_230342.jpg (198.9 KB, 0 views)
CallMeColt is offline   Reply With Quote
Alt Today
BGW

Golf car forum Sponsored Links

__________________
This advertising will not be shown in this way to registered members.
Register your free account today and become a member on Buggies Gone Wild Golf Cart Forum
   
Old 10-29-2017, 11:28 PM   #2
CallMeColt
Not Yet Wild
 
Join Date: Oct 2017
Posts: 9
Default Re: 2011 XRT 800E Refurbishing Thread

This post is just to upload the thermal camera pictures. In order, they are of the charger, charger plug inserted into cart, and lastly the batteries. All were taken at about the 4.5 hour charging mark. I have zero experience with gold carts but these temperatures seemed reasonable to me.
Attached Images
File Type: jpg flir_20171029T231609.jpg (26.0 KB, 0 views)
File Type: jpg flir_20171029T231621.jpg (34.4 KB, 0 views)
File Type: jpg flir_20171029T231636.jpg (41.7 KB, 0 views)
CallMeColt is offline   Reply With Quote
Old 10-30-2017, 04:04 AM   #3
NoleFan4Ever
MOD of all BS!
 
NoleFan4Ever's Avatar
Club Car
 
Join Date: Sep 2011
Location: Florida
Posts: 17,477
Default Re: 2011 XRT 800E Refurbishing Thread

Quote:
Originally Posted by CallMeColt View Post
Here are my questions;

1 - Am I going to mess anything up with the charger showing over 15 amps? Nope, normal for a PD3
2 - Could me installing a toggle instead of a new key switch be causing any issues? Like the reverse buzzer still sounding even when the switch is off not letting the cart move. Or the battery gauge always on. The buzzer will sound when you toggle to reverse. Someone probably added the gauge and it is hot all the time.
3 - Has anyone else heard their batteries bubble while charging? Yes they should and it is normal.
4 - Would anyone be able to tell me if I put the two smaller wires in the correct places on the batteries? I wasn't able to find a diagram in the thread with them for my cart. Can't really tell from your pic, but the red wire from the charging port should be on your main pack positive. This is the battery with the large red cable that runs back to your main contactor solenoid.


Any other pointers would be great.
See red above, but I did not know a PD3 was for a 36 volt cart. I thought they were only for 48v carts so I live and learn....
NoleFan4Ever is offline   Reply With Quote
Old 10-30-2017, 06:46 AM   #4
lockman1
What the ....?
 
lockman1's Avatar
Club Car
 
Join Date: Jan 2007
Location: N.E. Wisconsin
Posts: 14,899
Default Re: 2011 XRT 800E Refurbishing Thread

NO! Disconnect them before you burn something up!

Duracell GC2's are 6V batteries...(for a 36V system)
You have a 48V system, so you need (6) 8 Volt batteries!

The Charger is 48V!
lockman1 is offline   Reply With Quote
Old 10-30-2017, 10:16 AM   #5
NoleFan4Ever
MOD of all BS!
 
NoleFan4Ever's Avatar
Club Car
 
Join Date: Sep 2011
Location: Florida
Posts: 17,477
Default Re: 2011 XRT 800E Refurbishing Thread

Glad I was not going crazy...
NoleFan4Ever is offline   Reply With Quote
Old 10-30-2017, 10:18 AM   #6
NoleFan4Ever
MOD of all BS!
 
NoleFan4Ever's Avatar
Club Car
 
Join Date: Sep 2011
Location: Florida
Posts: 17,477
Default Re: 2011 XRT 800E Refurbishing Thread

Colt, what batteries were in it that you exchanged? They should have given you in like kind in regards to voltage as there was an exchange/core charge.
NoleFan4Ever is offline   Reply With Quote
Old 10-30-2017, 10:28 AM   #7
CallMeColt
Not Yet Wild
 
Join Date: Oct 2017
Posts: 9
Default Re: 2011 XRT 800E Refurbishing Thread

Thank you for pointing out the obvious. I feel like a fool! I was being meticulous on everything and somehow totally glazed over the fact that those were 6 volt batteries and not 8 volt. Somehow, that model came up when looking for replacement batteries for this cart and I just ran with it. Everything is disconnected and unplugged now. Nothing blew up overnight. Hopefully nothing was damaged. The people that accepted the core did not catch the difference in batteries either.

Looks like the GC8 is the batteries I need. Sam's Club will accept the exchange for the correct ones. My wife just talked to them. Thank goodness.

Last edited by CallMeColt; 10-30-2017 at 10:34 AM.. Reason: Add information.
CallMeColt is offline   Reply With Quote
Old 10-30-2017, 10:33 AM   #8
NoleFan4Ever
MOD of all BS!
 
NoleFan4Ever's Avatar
Club Car
 
Join Date: Sep 2011
Location: Florida
Posts: 17,477
Default Re: 2011 XRT 800E Refurbishing Thread

Be sure you are using that run/tow switch before you do any battery or electrical work on that cart. It will save your controller and electronics.....
NoleFan4Ever is offline   Reply With Quote
Old 10-30-2017, 09:00 PM   #9
CallMeColt
Not Yet Wild
 
Join Date: Oct 2017
Posts: 9
Default Re: 2011 XRT 800E Refurbishing Thread

Quote:
Originally Posted by NoleFan4Ever View Post
Colt, what batteries were in it that you exchanged? They should have given you in like kind in regards to voltage as there was an exchange/core charge.
They were the original Club Car marked batteries.

Quote:
Originally Posted by NoleFan4Ever View Post
Be sure you are using that run/tow switch before you do any battery or electrical work on that cart. It will save your controller and electronics.....
Yes, I was using that switch.

Quote:
Originally Posted by NoleFan4Ever View Post
See red above, but I did not know a PD3 was for a 36 volt cart. I thought they were only for 48v carts so I live and learn....
Solid copy on the notes.

Yes, the red wire from the charger is on the main pack positive... the same post that goes back to the motor.

The other small red wire goes to the back & I'm honestly not sure what it does. When I got the cart, it was hooked up to a negative. Thought that was strange being a red wire. I can't seem to trace it... I made it to under the dump body than back up toward the front & lost it. The only thing not working on the cart is the remaining headlight.

I might put a toggle on the battery gauge so it's not hot all the time... or maybe wire a relay so it's only on when the key replacement toggle is set to run.

Man, I feel so dumb!
CallMeColt is offline   Reply With Quote
Old 10-30-2017, 09:04 PM   #10
CallMeColt
Not Yet Wild
 
Join Date: Oct 2017
Posts: 9
Default Re: 2011 XRT 800E Refurbishing Thread

Exchanged the batteries & the correct Duracell GC8 are installed. Took a quick ride over to the neighbors & everything works as it should. Plugged it into the charger & it was above 15amps for a bit & went down to 15amps even. As per the advice in the batteries sticky, I'm going to let it do a full charge cycle before using it at all again.

Appreciate the help everyone.
CallMeColt is offline   Reply With Quote
Reply

Tags
xrt
Go Back   Buggies Gone Wild Golf Cart Forum > Golf Cart Repair and Troubleshooting > Electric Club Car


Thread Tools
Display Modes


Similar Threads
Thread Forum
2011 EZGO TXT 48v - Build Thread Lifted Golf Carts
XRT 800E Club Car Electric Club Car
Refurbishing Batteries? Electric Club Car
refurbishing 2005 ezgo Electric EZGO


All times are GMT -5. The time now is 05:13 AM.


Club Car Electric | EZGO Electric | Lifted Golf Carts | Gas EZGO | Used Golf Carts and Parts

Powered by vBulletin® Version 3.8.9
Copyright ©2000 - 2024, vBulletin Solutions, Inc.
This Website and forum is the property of Buggiesgonewild.com. No material may be taken or duplicated in part or full without prior written consent of the owners of buggiesgonewild.com. © 2006-2017 Buggiesgonewild.com. All rights reserved.