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Unread 01-21-2014, 12:22 PM   #1
Not Yet Wild
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Join Date: Aug 2013
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Default 97 CC Losing Power

Hey Modified CC Guys,
I am having problems with my system and need suggestions on a fix:

97 CC 48V Series lifted hunting buggy (July 2013)

#4 cables (August 2013)
Alltrax 500 amp controller pkg (August 2013)
HD Solenoid & F/R (August 2013)
(All of the above electronics purchased as pkg from site sponsor)

All 6 8v batteries (November 2013)
D&D speed/torque motor (December 2013) (site sponsor)
PowerDrive Charger checked out by pro service (January 2014)

Ok, with that background, there are 2 issues with charging the system that seem to be related.
Issue #1:
Since purchasing the cart in July, when I charge the cart for 12-18 hours, the charger will usually remain at the 15-20amps level without moving. Having read the threads related to the OBC, I have disconnected the cables to reset the OBC. After reconnecting the batteries and upon charging, the charger will cycle back down to 0-5amps on the 1st charge, then return to the constant 15-20 amp position on subsequent charges. I have checked each battery individually after charging; the #5 &#6 batteries (on the passenger side) are inconsistent with the other 4 (6-7 volts on 5&6 vs. 8-9 volts on 1-4). I would think that the obc is failing before the charger reaches those last 2 batteries. My cart service pro has checked out the charger as fine, so at this point, I am leaning towards taking the cart in for professional service. What say you?

Issue #2:
I believe that this issue is related to issue #1. After an overnight charge, the cart will run as it should for 5-20 minutes, depending on the terrain and load. It will run at up to full speed & power, then gradually slow to a stop with no power. During this run time, the analog power meter will show 3/4 power at baseline, falling to below 50% on acceleration and falling to below zero when it comes to dead. Once it fails, if I rest the cart for 20-30 minutes, it will run for a short period afterwards. This issue has surfaced since installing the D&D motor in December, but I cannot draw it directly back to a motor issue, as it performs as it should, albeit for a very short drive. I will say that the run time is decreasing each time I take it for a drive. Once again, what say you?
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Unread 01-21-2014, 12:28 PM   #2
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Default Re: 97 CC Losing Power

sounds like a battery issue to me. What are the actual readings of each battery?
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Unread 01-21-2014, 12:49 PM   #3
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Default Re: 97 CC Losing Power

batteries are new, I even returned the #5 & #6 batteries that read sub-8v after the 1st run. those too are now sub-8v, while the 1-4 batteries are 8v+...
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Unread 01-21-2014, 12:49 PM   #4
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Default Re: 97 CC Losing Power

Make sure the new #4 gauge cable still goes thru the OBC and that the charger socket is connected to the main pack positive, meaning you are actually charging all 6 batteries.
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Unread 01-21-2014, 12:51 PM   #5
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Default Re: 97 CC Losing Power

What are the ACTUAL readings. It def sounds like a battery issue. 8.07 volts is 50 percent. Do you have any accessories running on those two batts only?
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Unread 01-21-2014, 01:02 PM   #6
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Default Re: 97 CC Losing Power

What is the reading for the whole pack?
Attached Files
File Type: pdf SOC Batts.pdf (71.3 KB, 0 views)
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Unread 01-21-2014, 04:15 PM   #7
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Default Re: 97 CC Losing Power

I'm with Sergio on this one. Chargers don't charge from right-to-left or vice versa. They charge the whole pack simultaneously. I think your *new* battery pack is wired wrong, and at least one (if not two) batteries aren't even getting charged at all. Your basically running on 4 or maybe 5 batteries. Thus the short run times - and the reason why you replaced #5 & 6 already.

Look at any 48v manual in the stickies and the battery wiring/pattern. I'll betcha you've got one or two batteries turned around and are not connecting the pos. from one battery to the neg. on the next battery (and so on).
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Unread 01-22-2014, 12:25 PM   #8
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Default Re: 97 CC Losing Power

Thanks Sergio & Joesam,
I took a closer look at my connections & realized that the positive lead from the charger group was connected to #4 instead of #6. I probably did that when I replaced the battery pack in November. Corrected & now back on charger. Now my question is about the life of #5&6.
Prior to correcting & charge, batteries 1-4 were at or close to 100%. My multimeter is analog not digital, but it read halfway between 8&9v. The bad news is that #5&6 read at about 7v each.
When I connected the charger after correcting the positive lead, the charger meter went to about 8 amps & is now at about 2 amps, 15 hours into the charge.
What does that suggest?
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Unread 01-22-2014, 12:43 PM   #9
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Default Re: 97 CC Losing Power

Let the charger cycle. It might take a few charges to balance the pack back out. You can bump those 2 up with a 12v charger as well, just dont leave it on too long - 15 to 20 mins max.
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Unread 01-22-2014, 01:11 PM   #10
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Default Re: 97 CC Losing Power

Ditto sunoco - a little half hour boost with 12v (@ 2amps or less) on each of those abandoned batteries - prior to charging the whole pack - is a good way to get them recovered and in-step with the others. Two or three repetitions of that process oughta do it.
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