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Unread 09-19-2010, 04:53 PM   #1
Not Yet Wild
 
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Default 91 Club Car power issue, deer scouting cart

Howdy all, love the site and this is my first post.

I have a 91 club car that has vglide and resistors (single solenoid), motor PN:1012191 Model:5BC48JB764.

I got this in awesome shape for $100 bucks....brother in law wanted me to get a bad boy buggie, but they look they they are not made well...and I can build this to my specs :o) and the WAF must be met.

I tore it down to the frame and started the build. I replaced the solenoid and and vglide contact just because mine looked real used. all wires are 4gauge and the entire cart is rewired. The cart went back together perfect and I learned this model in and out.

Here is my problem, and I think I know the answer. It runs great on the flat and then seems to start loosing small amount of power. When it was full charged the wife and I took it for the maiden voyage. Up hill for about 700 feet it was a slow dog...flats were fast. Today (just me), I did loops in the yard and up and down like 30 times. About 20 min and battery gauge was down to 65%. It almost felt like it would barely make it up my yard...and its not that much of a slope.

The cart has a lift and bigger tires, the tires are more balloonish and ride very smooth with less friction than stock.

The batteries that came with it are suspect. They all had fluid, some more than others. They were stone dead. I put them on a 6volt charge individually and got them to 100%, I had to charge each one maybe 4 times. The batteries are ballooned out quite a bit. They had a drywall screw holding one wire on when I got it. I made all new 4gauge wires. Total voltage is 37.6 when fully charged. I load tested them with 100amp harbor freight tester and they all sit right on the line between WEAK and OK...not much forgiveness on the OK part...small. All connections have new nuts and are cleaned.

The date on the batteries are June 2006.

Do I need new batteries?

I see The Beast cart 36v climbing hills and logs....36volt should be enough to put-put around the farm. I am not looking to pull anything or speed. I want scout and take rides.

Would going to 36volt solid state (cheaper than 48volt conversion) help too.

Is the change from 36v to 48v that great, or is it the solid state that makes the difference.

Looking for some options.

Thank you for your time,
I have read thousands of post building this cart...I need some honest opinions that work for my scenario. This site is great!!!!!

Smoman
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Unread 09-19-2010, 05:05 PM   #2
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Default Re: 91 Club Car power issue, deer scouting cart

Congrats on a great first post and NICE looking cart..... I can see you live in some hill country.

Your cart is the perfect candidate for a 48 volt conversion.... A solid state conversion and boost to 48v is the best mod you can make. Hands down.

I did it to both of my 89s (same system as your 91) they become what I had previously only dreamed they could be... I used to look for hills to climb... We once took them to a dozer pit just to see what they could climb. There is plenty of info here on the site about this. Just put 48v conversion into the 'google search' box. Pm me with any questions you have. I got pics of how to mount the potentiometer, etc. The Six 8volt batteries will drop right in to replace the dying batteries you have now.
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Unread 09-19-2010, 05:15 PM   #3
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Default Re: 91 Club Car power issue, deer scouting cart

if your batts are 6 years old and they were stone dead already while you might not need them this very minute i would replace them.........a good 6 volt battery fully charged is going to read almost 7 volts............funny but a 6 volt battery at 6 volts is dead, so if you already redid all your battery cables we know there good but i would replace the batteries................scotty no one caught it *** if i ain,t good..................lolol.......................
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Unread 09-19-2010, 06:01 PM   #4
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Default Re: 91 Club Car power issue, deer scouting cart

SCOTTYB has been down this road before and has good write ups for reference and is right dump the weak 6 volt batterys and go with 8 volt high 20 hour amp rating, do solid state control conversion with PB-6 and HD 48 volt solenoid and proper diode and resistor to 48 volts, beef up the F&R control with heavy brass bar stock, then while retaining your 36 volt motor will turn your HO HUM into WOW.
TRY IT YOU WILL LOVE IT.
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Unread 09-19-2010, 07:13 PM   #5
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Default Re: 91 Club Car power issue, deer scouting cart

Thanks for the responses,

How can I upgrade for the time being to solid state and be ready for 48v in the future. I really think my batteries are shot...so i have not even seen what 36volt can do. First electric cart ever...but solid state would be more efficient and seems parts are cheaper for 36v. Just a thought....

six 6 volt batteries
36v-48v controller
PB-6 and some wiring.
I see some controllers that are 36-48 250amp for $50 bucks...

Smoman
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Unread 09-19-2010, 07:16 PM   #6
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Default Re: 91 Club Car power issue, deer scouting cart

I only have 400 into the cart with lift, everything else i made, welded or had my dad CNC at the shop he works at. Roof got for 40 bucks and made the supports out of conduit. Amazing what you can do for cheap.

Smoma
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Unread 09-19-2010, 08:19 PM   #7
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Default Re: 91 Club Car power issue, deer scouting cart

Quote:
Originally Posted by smoman View Post
Thanks for the responses,

How can I upgrade for the time being to solid state and be ready for 48v in the future. I really think my batteries are shot...so i have not even seen what 36volt can do. First electric cart ever...but solid state would be more efficient and seems parts are cheaper for 36v. Just a thought....

six 6 volt batteries
36v-48v controller
PB-6 and some wiring.
I see some controllers that are 36-48 250amp for $50 bucks...

Smoman
If you are going to buy new batteries, go ahead and get the 48 volt pack instead of the 36 volt pack..... usually cost less than $100 more

the controller you buy should be a minimum of 400 AMPS with that lift on the cart (personally, judging by the pic you posted I would reccommend a 500 AMP controller). Anything less will fail. figure to spend a couple hundred dollars for a good controller I prefer GE, but Alltrax makes a good unit as well.

The PB-6 is an expensive unit. Consider a PB-16 instead. You'll save about $50 and the unit works exactly like the PB-6.
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Unread 09-19-2010, 09:48 PM   #8
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Default Re: 91 Club Car power issue, deer scouting cart

36v is for golf
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Unread 09-20-2010, 11:01 AM   #9
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Default Re: 91 Club Car power issue, deer scouting cart

Listen to what RABBITREBORN and SCOTTYB say dont short yourself by buying new 6 volt batterys now and wishing later on that you had gone with 8 volts instead? I have done real top end high power conversions where I used ( 8 ) 6 volt of highest 20 amp hour rating batterys to try and stretch range but this means extra HD wiring and loss of space in bag well plus the added weight and from what you say this isn't what you want anyway?
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Unread 09-22-2010, 09:13 PM   #10
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Default Re: 91 Club Car power issue, deer scouting cart

Update: Batteries were bad...I got me new batteries from NAPA. They are 220ah DEKA batteries with a 30 month warranty $89 per. DEKA has a stellar track record with batteries from what I have been researching. Anywho, I made all new 4ga welding cable wires. I replaced everything except the small solenoid wires.

A trick was to get open crimp on ends for the vglide side and hit them with a hammer flat, they fit right inbetween the plastic seperators. I made some of my own with copper tube and soldered all. I color coded everything with colored elec tape. I ran all over today, climbing hills and even a real steep 1000 yard climb with 2 ppl in the cart. I got to the top and checked the wires for heat...the vlgide was cool and all wires were perfect. The 4g wire made a huge difference in heat.

Batteries were the biggest issue, I am not breaking them in.

So now I know a 36v cart will do what I want...I am sure I could go faster with 48v, but this cart is so simple...and works for scouting. I may get the motor rewound for some more torque and I am set.

Thanks for all your help, 48 volt will be in the future but 36v is just fine (I know, for golf :o)

Smoman
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