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Unread 09-26-2019, 09:18 AM   #1
Not Yet Wild
 
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Default 2005 Club Car DS slow uphill

Looking for some help. I've searched the forums and tried the typical fixes but haven't had any luck.

I recently picked up a 2005 Club Car DS that needed new batteries. I replaced the 4 24 volt batteries with 6 new 8 volt batteries. At the same time I replaced the pack wiring as well as the wiring to the motor and when running the positive I was sure to run it through the sensor. (I used good quality wiring the same size as stock) I am still in the break in period for the batteries where I am running them down to about 50% and then charging them completely. When they are fully charged I am getting a reading of 52 volts across the pack and the meter on the dash shows that they are fully charged. The cart runs well on flat ground including being quick to accelerate from a stop. The issue that I am having is that when I go up even the slightest of grades the cart slows to around 8 or 9 mph and the volt meter on the dash drops to almost half. I have replaced the speed sensor and added the upgraded magnet which has increased the flat ground speed from 13 mph to 16 mph and downhill to 23 mph but did not improve the speed going uphill. Any advice on what to try next would be greatly appreciated.
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Unread 09-26-2019, 09:28 AM   #2
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Default Re: 2005 Club Car DS slow uphill

The "Negative" cable is the one that runs through the OBC and that hole in the OBC cannot be safely enlarged.

If the digital voltmeter on the dash is dropping in voltage, it could be a bad battery or cable between batteries.

Get some long alligator clip leads and clip the voltmeter (set to 20vDC) to each individual battery as you drive up the hill to see if any battery is dropping significant below the others in voltage.
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Unread 09-26-2019, 11:30 AM   #3
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Default Re: 2005 Club Car DS slow uphill

Thanks for the reply.

If its the negative that runs through the sensor then that's how I ran it. It has been a couple months since doing that so apparently I remembered incorrectly. They are all brand new battery's that all test over 8 volts individually when fully charged. I also replaced all the cables between batteries. Don't think it is a battery or cable issue. Unless it could be a cable that runs between the motor and the controller. I have not changed any of those.
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Unread 09-26-2019, 11:45 AM   #4
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Default Re: 2005 Club Car DS slow uphill

While the cables that run between Controller and Motor are the most important ones to replace as they will carry the most current, they would not cause the voltage as measured on the pack to drop.

If you don't want to perform the troubleshooting tests at least verify that every cable is in direct contact with the lead surface of the battery post and any other small ring connector is on top of the large lugs.

Do any of the cables or battery posts feel warm once you get to the top of the hill?
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Unread 09-26-2019, 12:32 PM   #5
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Default Re: 2005 Club Car DS slow uphill

The voltage meter on the dash is showing the voltage at the controller since that's where power comes from for the meter.
You said it drops by half, so is it showing 25V when driving up-hill?

That indicates a poor connection or a bad battery.
You need to check the actual pack voltage WHILE driving with a separate meter.
Also check Each battery Individually while driving.
This is the only way to determine a bad connection, or a failing battery. Checking battery voltage with the pack at rest does you no good since the problem does not happen while the cart is sitting still.
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Unread 09-26-2019, 03:54 PM   #6
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Default Re: 2005 Club Car DS slow uphill

I will check with the volt meter while running. Not sure if the batteries are hot, haven't touched them. All wires are brand new with good solid clean connections. The voltage meter on the car I believe is wired directly to the pack, not the controller. I believe it works just like if I was to hook the volt meter across the pack to get a total voltage. What are the chances that one of the brand new batteries is bad? Can a battery read at or higher than it's stated voltage when charged and still be bad? Maybe it would help to say that even though the batteries that were in the car before needed to be replaced they did function and I had the same issue with those. Ran normal speed on flat surface and then slowed up hill. Hoped that just changing out the batteries would help with this but clearly it seems to be something else.
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Unread 09-26-2019, 04:00 PM   #7
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Default Re: 2005 Club Car DS slow uphill

Yes a new battery can be bad, but notice I said "battery post" temperature, not battery being hot.

If there is a high resistance path in the system it will get hot when the cart is going uphill.

If you have a temperature gun use it, otherwise just put your hands on every battery post and cable to see if any is hotter than the others after you go up a hill and the cart runs slow for a while.

Can you tell us what the voltage reading is or are you just using one of those "battery gauge" type meters on your dash?

A brand new fully charged battery should read around 8.6v or more.
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Unread 11-07-2019, 10:03 AM   #8
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Default Re: 2005 Club Car DS slow uphill

Finally got around to load testing. All batteries read around 8.4 at idle. I should probably mention that this is a 48 volt cart that had 4 12 volt batteries. I replaced them with 6 8 volt batteries. When cart is running the voltage immediately drops to anywhere between -1 and 1. I checked them all individually and they all have the exact same reading. I tested them by running alligator clips to each battery while driving the cart. The drop in voltage happens immediately when you drive on flat ground.

Again any help is appreciated.
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Unread 11-07-2019, 11:11 AM   #9
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Default Re: 2005 Club Car DS slow uphill

If You had your multi-meter leads clipped directly on each individual battery + and - posts and it shows that much voltage drop, the battery is trash.

Are You sure the batteries are being charged?

Measure each battery near the end of the charging cycle (while still charging) to make sure they go up to approximately 10v.
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Unread 11-07-2019, 01:18 PM   #10
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Default Re: 2005 Club Car DS slow uphill

All 6 batteries are brand new. I have a hard time believing that that they are all trash. Cart runs fine just seems to be a little slower uphill than it should be. That is the issue that I am trying to resolve. Not sure how I can be getting those readings when the cart is running full speed with plenty of power. If they were all really putting out - voltage then the cart wouldn't run. Fairly certain that the batteries are being charged fully.

The cart runs great except for slowing down to about half speed when pulling any inclines.

Maybe I have something wired wrong?

Could the voltage meter be messed up?
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