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Unread 09-06-2011, 03:08 PM   #1
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Default Club Car just quit - batteries dead & won't charge

My girl friend's Club Car just quit this weekend. Still trying to find out model/year etc. Bought used in 2007 but prob 2005 +/_, and it lightly used 1 to 3 weekends a month. Looks similar to LOCKMAN1's except not as raised up.

She was gone and guests used it. Went 100 feet and it quit. They towed it home about 3 blocks. Hope they put on tow mode, but I just don't know.

History:
Last year a spare cable fell across terminals and one battery fried at the terminal and the sides bowed out. Replaced that battery and all five connecting cables and all has been well. No I did not put in tow mode before changing cables but will in the future.

Two weeks ago, batteries were filled w/ distilled water. Took almost a gallon for all six. Two terminals beginning to corrode. Cleaned and sprinkled baking soda to affected areas.

Charged Friday and used over the weekend. Then it quit Sunday afternoon.

Used a non loading type of battery checker of unknown quality which indicated all batteries were dead. All wiring appears OK. Only fuse found was OK. During last time batteries ran down, reverse beeper still beeped even though car wouldn't go. This time it does not beep at all. Headlights came on OK but weak (only on two batteries I think).

Tried to recharge, and instead of jumping to 5 to 10 amps, the charger meter only registers 1 to 4 amps and then instantly drops to near zero.

The cart is 2 hours away but I will probably go up there this weekend to work on it.

Any suggestions as to probable cause or things to check or info about the car I need? Thanks.

Just found out it is a DS model, probably about a 2002 if that helps.

Last edited by rivercity1941; 09-06-2011 at 03:36 PM.. Reason: Add model info
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Unread 09-07-2011, 11:25 AM   #2
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Default Re: Club Bar just quit - batteries dead & won't charge

I always start by removing and cleaning all battery cables to confirm good connections. It sounds like your batterys may be shot? You need to get a digital volt-amp meter ( Harbor Freight $4-6 ) to confirm each batterys condition. 6 volt batterys with 3 fill holes 6.37 volts, 8 volt batterys 4 fill holes 8.49 volts, 12 volt batterys 6 fill holes 12.73 volts ,Total pack voltage 50.96 and record for forum.
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Unread 09-07-2011, 12:22 PM   #3
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Default Re: Club Bar just quit - batteries dead & won't charge

is the charger when the amp gage goes down is it shutting off or just staying there like its charging at 1 amp or so? try and find that out..........take a digital voltage meter with you and take voltage reading off of each battery and than the pack...........check all cables make sure they are clean and tight.....grap and twist........check all other cables also look for any that look burnt right at the connector.................check the receptical fuse, take something so you can jack the rearend up for possible testing purposes..........see if soleniod clicks when you press pedal ( rear end jacked up ) also take a peice of six gage cable to jump soleniod if needed...............some duct tape or elec. tape if needed......and if you can find it a wiring diagram for the cart, you can also load test the batteries with the voltage meter............................
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Unread 09-07-2011, 12:44 PM   #4
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Default Re: Club Car just quit - batteries dead & won't charge

Thanks, I will do what both of you have suggested. Batteries may indeed be shot, but it was working just fine at normal speeds until the moment it quit, so I hope not.

As far as charger, I will have to look closely because I think it was just above zero, but I am not really sure. Thanks again.
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Unread 09-11-2011, 06:56 PM   #5
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Default Re: Club Car just quit - batteries dead & won't charge

Problem appears to be solved after I did what you suggested - basic maintenence may have prevented.

Problem was one or probably two bad wire/lug connections. All were OEM cables replaced last year. Appeared fine at first tug. Removed and soaked in baking soda and diet tonic water (became very blue). Rinsed. Then while sanding corrosion off lugs, two lugs came loose. The ones that came off were from the most corroded terminals. Replaced w/ O'Reilly 18-inch 4 ga cables w/ aluminum lugs (only place in Mountain View, Arkansas to buy on Saturday). Charged fine. Voltage was at 8.5 /51.0 volts (only one decimal place on meter). Heavily coated all exposed metal w/ electronic grease.

Only mystery is one wire that doesn't look factory that we cannot agree on where it went. I say negative, my friend says positive. It does nothing when put on neg but sparks slightly when touching pos. Cart works, lights work, horn works so I figure a redundant ground that I will leave off for now.

Lessons learned:
1) Maintain water level better.
2) When checking water immediately tear down and clean any corrosion.
3) Keep spare cables.
4) Always put in TOW mode before doing anything to batteries.

What I would like to know is should the charger be left on while we are away?
As mentioned, cart is used lightly one to three weekends a month year round. Mainly a few trips from the house to the river dock 1/4 mile away w/ one big hill. Also a mile round trip through hay fields to give the dogs some exercise if field/weather permit. Sometimes twice if dogs are asking (ie sitting in the cart waiting).

Girl friend says leaving on charger is what is probably causing corrosion so she leaves it disconnected and charges when we get there. I say charger will cut off automatically and then provide a trickle as needed (says so on charger label). Also, I figure running down batteries and leaving low probably isn't good either. Who is right? Or should I say does she need to change her opinion because I am smart enough to know I will never be right.

Thanks for your help!!!
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Unread 09-11-2011, 08:11 PM   #6
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Default Re: Club Car just quit - batteries dead & won't charge

if your using the cart that much you don,t need to leave it on the charger the batteries if they are good and hold a charge will be fine......you are right about the charger so you can tell her that but its not nessisary to leave the charger on the cart..........and your right about the basic maintence, if everyone did it we would have a lot less golfcart problems......thats why you see me preach it..................................
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Unread 09-12-2011, 11:21 PM   #7
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Default Re: Club Car just quit - batteries dead & won't charge

Quote:
Originally Posted by rivercity1941 View Post
-snip- Girl friend says leaving on charger is what is probably causing corrosion so she leaves it disconnected and charges when we get there. I say charger will cut off automatically and then provide a trickle as needed (says so on charger label). Also, I figure running down batteries and leaving low probably isn't good either. Who is right? Or should I say does she need to change her opinion because I am smart enough to know I will never be right.
Here is a quote from the CC Battery Service Manual

Long-Term Storage Charge
IQ System, PowerDrive, and Precedent vehicles with PowerDrive chargers are designed to be left connected with AC power to the charger during off-season or long-term storage. The onboard computer will automatically activate the charger every 15 days. To return the vehicle to service, unplug the charger DC cord, wait 15 seconds for the computer to reset, and plug the charger back in. WARNING. This will ensure the batteries are at their optimum charge prior to returning the vehicle to service.
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Unread 09-13-2011, 11:09 PM   #8
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Default Re: Club Car just quit - batteries dead & won't charge

Sounds great. Thanks! So on any given weekend, drive it till it slows down, then charge. If we do charge when we leave for a week or two, do we need to do the pause for the computer to reset, then plug charger back in for a few seconds???
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Unread 09-13-2011, 11:30 PM   #9
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Default Re: Club Car just quit - batteries dead & won't charge

I noticed you mention cables from O'Rileys, they will get you out of a weekend pinch but the ends are not solid and will compress when they get warm then get more loose and possibly melt a battery lug. they are stamped onto the wire strands and not for high amp continous duty use.
please replace them as soon as possible with the correct type.
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Unread 09-14-2011, 12:23 PM   #10
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Default Re: Club Car just quit - batteries dead & won't charge

Thanks, will do. But they actually look more solid than what came from the dealer. I am not impressed w/ them. Any suggestion of where to find better ones?
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