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Electric EZGO Electric EZ GO Marathon, Medalist, TXT and RXV.



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Old 07-25-2013, 01:03 PM   #1
Wyatt2261
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Default 2 years out of Batteries

93 Marathon 36 v with 22" tires/ 2 speed EMP motor / 700amp controller / 6gauge wires / 6" lift. Cart is used for hunting over rough terrain. With new batteries can get about 5 or 6 miles, however batteries are only lasting two seasons. First set was Sams batteries (died at 23 months) Second set were Trojans T105 ( dead at 28 months. Currently running US 2200 bought on 9/2011, they will not make another season. Current readings are: 6.17, 6.15, 6.13, 6.19, 6.19, 6.17 = 37.00. Using a Clarke (Lester) 36v auto charger.
I Never let battey pack go below 70% of discharge. Always check water levels.
Its a 3 mile run to stand and back at slow speed, so cart get charged after each run.

Not sure how to fix.
1) Bigger batteries?
2) Smart Charger?
3) Go to 48 volt?
Or is this what I should expect.
Anybody have any suggestions?
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Old 07-25-2013, 01:37 PM   #2
patgrim00
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I would upgrade wires from 6 gauge to 2 gauge every one has recommended 4 at a minimum for my 500 amp controller
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Old 07-25-2013, 01:46 PM   #3
Wyatt2261
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Default Re: 2 years out of Batteries

I miss stated the wire size, they are 4 gauge.
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Old 07-25-2013, 02:00 PM   #4
patgrim00
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Oh ok
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Old 07-25-2013, 02:16 PM   #5
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Default Re: 2 years out of Batteries

A good start would be to monitor and record/post the "finished" voltage of your battery pack after charger shut down and 12 hrs rest (38.2 volts would be 100 %). Your charger may be coming up short (shutting off too soon), allowing some room for sulfation to creep in. Also, you could record/post the max. pack voltage (just before charger shutoff). This is to make sure your charger is working correctly. Post results for comments from the "gang". Something doesn't seem right, I think you should be able to do better. - Hope this helps - RAY

Last edited by bigstik40; 07-25-2013 at 02:20 PM.. Reason: add comment
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Old 07-25-2013, 02:33 PM   #6
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Default Re: 2 years out of Batteries

Thanks,
Will post results tomorrow.
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Old 07-25-2013, 02:55 PM   #7
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Default Re: 2 years out of Batteries

I have been where you are at.

My current set up is 91 Marathon 36v with 22 inch tires and lift. I have 2 ga wiring, D&D speed/torque motor, HD FNR and a 650 amp Alltrax. Using Trojan T105's that are 3 years old.

I originally started with the 2 speed EMP, 4 ga wire and Sams batteries with a 500 amp Curtis. With this set up I was only getting 4-5 miles range and the Sam's batteries only last 2 years (they are junk IMO).

I eventually upgraded the wiring, went to the 650 Alltrax and added the Trojans. I was getting a little more range but not as much as I would like and the power and speed were really not what I wanted.

The EMP 2 speed is really built for handling only about 400 amps max. I got that info from Chuck at EMP. He is very nice guy and I am not bashing the company in any way. I just dont think the motor is built for the heavy/hard off road use my cart was seeing and also the high amp controller.

Anything more than around 400 with the EMP is just wasted amps and I actually burnt up the motor twice with my amperage as well as having a lot of heat issues with the wires and FNR. I am not sure if you have had those problem or not yet.

Last year I changed over to the D&D motor. There was an immediate night and day difference and it had more torque than the EMP torque setting (in fact it has so much that I have considered turning down my amperage) and more speed than the EMP speed setting.

I also can run all day with no problems. I don't know exactly what my range would be but I would guess at least 10-12 miles easy and I really think it would be more than that.

I don't know why your Trojans did not last any longer. It could be that with the wasted amps and if you have any extreme heat (which is also wasted power) that could be part of the problem. My sister has a stock PDS and I put the US2200's in it. They are very comparable to the Trojans. Both are good batteries IMO and you should be able to get more than 2-3 years out of them. Maybe your charger is not getting them to 100%.

I would recommend going with 2 ga wiring. ScottyB sells some of the best cables made and is a site sponser on here. I also would either get another motor that will handle the 700 amps or get a 400 amp controller to go with the EMP motor. Check all of your wires and the FNR switch. If anything is getting so hot you can't touch it that is a place you are losing power/battery life. It is like a hole in a fuel line.

I was so frustrated at one point with my Marathon I though tabout selling it and starting over but now I could not be happier........ well maybe if I went to 48v I would be a little happier! LOL
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Old 07-25-2013, 03:31 PM   #8
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Default Re: 2 years out of Batteries

Your cart looks like mine. LOL!!! When I talked to Chuck several years ago he told me the EMP motor would only draw about 400 amps from the 700 amp controller. I have been pleased with the motor has all the power I need and way to much speed. If I Knew for sure changing the motor would fix my problem I would do it. Have not seen any heating issues, but honestly I havent really been looking for that. What D&D motor did you purchase?
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Old 07-25-2013, 03:49 PM   #9
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Default Re: 2 years out of Batteries

I went with the D&D 170-010-0002. Peak HP is 8.3 and speed up to 14mph on stock tires.

Your situation with not much run time sounds so similar to mine. I just think that the high amp controller and 2 spd EMP motor is not a good combination for some reason. It could be that a Marathon motor period, even if it is rebuilt, is just not very effecient?

All I can tell you for sure is that my new motor seemed to cure my problem with run time.
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Old 07-25-2013, 06:07 PM   #10
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Default Re: 2 years out of Batteries

See if your charger is putting out 44 - 45V when it's on it's final charge. This will be after several hours and the ammeter has dropped to near 0 - 3amps.
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