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Unread 10-30-2008, 09:15 AM   #1
Getting Wild
 
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Default New to site -- '98 CC problems

Hi; Glad to have found this site. I have 7 1998 Club Cars 48v's. Batteries are 2006 exides, with new wires. Some of the problems i've encountered and am trying to fix include:

One cart, from day one of buying it used, seemed to run really fast then die as if it was fully discharging its battery pack within seconds of hitting the gas. It won't run at all now, but will charge.

another charges, again won't run.

A battery in one of the two non-runners was wired wrong. I fixed that --though the wire/nut seems to be welded to the post now.


Third one won't take a charge. was my main "utility cart" and just upped and quit one day. (kind of like my employees!) batteries are tapped out at 1-2 volts each.

I did continuity checks on all the wiring, everything seems ok. chargers are ok, as they work with no problems on the other carts. I don't get a "total" voltage reading across the pack though. it will give me 18v for each pair and around 8-9 for each, but won't pick up/read any voltage going beyond a pair.??


the two non-runners have low fluid levels, i'm charging them then intend to top up today. would visible plates prevent them from running?

I'm also going to try the small post jumper test to check the two to see if it's the obc as indicated in another thread. any other suggestions??? Looking to see how to test each of the components instead of trying to replace things until it works--that'd be a bit expensive! Thanks for your help.


BTW, when i installed the new batteries, ($68 ea. back in '06--if it's ok for me to post where i got that price, lmk-- after researching i found that where i got them had the best prices, even better than if i had gone to Deka --not far from me- and picked them up myself) if found that 1/4-in wall thickness, 1.5 to 2 inch wide aluminum angle stock worked well as a replacement for the corroded out battery trays. I just sawzalled the rotted one off, ground off the weld remnants and pop-riveted the new stock in place. inexpensive and solid, quick fix.
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Unread 10-30-2008, 09:23 AM   #2
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Default Re: New to site -- '98 CC problems

Batteries First! The lead plates must be covered in distilled water at all times. Exposure to air is harmful. Charging exposed plates is damaging the battery. You should not go any further until you have a good voltage reading across the pack 48-50 volts +-....Maybe they are not consistently wire right? Check to see that they are cabled neg to pos all the way from one end to the other. Find the end of the pack and you should get readings in increments of 8 v all across, 8 16 24 32 40 48v? If you don't see this then the batteries are not connected in series properly. If you don't see this the chargers won't work and the carts won't run.
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Unread 10-30-2008, 11:30 AM   #3
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Default Re: New to site -- '98 CC problems

i'm watering them right now. (distilled) I'll quadruple-check the wiring and do the voltage tests again. no change since trying to put a charge on them. only 1 cart had the plates exposed, it has been sitting about 2 years--was the first one to stop working--the solenoid clicks on that one. the other that will charge but won't run doesn't give me a click when i step on the pedal. thanks for replying, i'll update if i find anything different.
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Unread 10-30-2008, 12:02 PM   #4
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Default Re: New to site -- '98 CC problems

ok, simple mistake, had the voltage range on my meter set wrong. i've got full voltage across all the batteries on the two that won't run, wiring is correct. the one that won't take a charge only shows 12 volts across the pack, wiring is correct.

update ... easy fix for one of the non-runners; orange cable's terminal end at the motor was broken. new lug ... battery is topped off and charging, did a 1/2 mile drive with it, this one is fixed. two to go!


on the other non-runner that is taking a charge, jumping the two main terminal lugs on the solenoid with it jacked up, on and gas depressed did nothing. same setup, jumping the no.6 battery negative to the yellow wire small terminal on the solenoid did nothing. is there a main frame ground somewhere on these that i should check?
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Unread 10-30-2008, 12:48 PM   #5
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Default Re: New to site -- '98 CC problems

Welcome to the forum x-bird......................
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Unread 10-31-2008, 07:19 AM   #6
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Default Re: New to site -- '98 CC problems

Thank you rusty. still scratching my head on these other two.
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Unread 10-31-2008, 07:45 AM   #7
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Default Re: New to site -- '98 CC problems

No frame ground on an electric vehicle....everything gets two wires!
We need to establish which system your carts have......Resistor coils behind the batteries or controller box bolted to the frame high up and behind the seat. Are they all the same?
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Unread 10-31-2008, 07:50 AM   #8
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Default Re: New to site -- '98 CC problems

controller box (silver) behind the seat, single solenoid non-reagan. yes, all carts are the same. the only difference is that one cart--the one that won't charge at all, has different style seats (individual headrests) and black windshield/roof frame.
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Unread 10-31-2008, 07:58 AM   #9
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Default Re: New to site -- '98 CC problems

HAve you confirmed the year by serial # and downloader the wiring diagram?
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Unread 10-31-2008, 08:20 AM   #10
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Default Re: New to site -- '98 CC problems

yes, they are 98s, i will check the oddball seat cart though. and i did dl the wiring diagram.
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