EZGO Series Cart - New Batteries - Horrible range

[Exchangegeek]

Is there a way to test the motor or controller or should I start replacing parts to improve the range on our 2005 EZGO Series Cart?

We recently bought a 2005 Series cart and brand new batteries and 2 AWG cables and we can get maybe 5 miles before the batteries are 50%. We have an LED meter but I also checked it with a voltmeter to make sure those readings are correct.

The range is terrible to say the least and I am willing to buy either a motor or controller to fix the problem but I don't know where to start. My gut tells me to test/replace the motor since it is what is pulling the power. The controller just regulates it right?

[JMGreco]

You mention that your battery pack is new and that you are getting down to 50% on a five mile ride. I agree that something is wrong but would start by getting more information on your battery pack. Is your cart 36v or 48v? How are you measuring your voltage to determine you are at 50%? Start by telling us what your voltage is when your pack is fully charged. Provide total pack voltage as well as individual battery voltage. If any of this is Greek to you, let us know and we can walk you through it. You need to get a digital volt meter (DVM) to get accurate voltage readings.

[Exchangegeek]

Thanks for the response. 36V system and I bought the batteries brand new myself and put them in. The cart runs just fine, just not for long!

I installed a cheap LED meter, but when I noticed the horrible range, I put a voltmeter on each battery and verified that they are indeed being discharged.

The range is so bad that my son attempted to go to his girlfriend's house (3 miles away) and the batteries dropped to 10% when he was almost home and could not drive anymore. He now knows about the 50% "rule" .

[JMGreco]

What brand and model batteries are they? Batteries have a date stamp on them on one of the two terminals, understanding you bought them new, verify the year they were made by checking the stamp. May be a code, by telling us the brand and model of your batteries, we can tell when they were made. What charger are you using? Can you verify the charger is getting your pack fully charged to 38.2V after a full charge?

[JohnnieB]

If the cart has tall, low pressure tires, the battery pack made up of super economy grade batteries, not all 13 high current cables were replaced with 2Ga, the stock solenoid is being used and the stock F/R switch is being used, 5 miles just might be all the range the cart is ever going to get on a single charge until all components in the drive system are compatible.

What is the tire diameter?
What is the max air pressure stamped on their sidewall?
What is the Make and Model of the batteries (or at least the nominal voltage and AH rating - 6V-225AH is standard for a 36V cart with a series motor)
What battery charger are you using?
What is the pack voltage and individual battery voltages after the batteries have rested 12 hours after the charger shuts off automatically? (Typically 38.2V for a 36V pack and 6.37V for a 6V battery)
What type terrain was cart driven over?
Does the cart push freely by hand?

[Exchangegeek]

Stock 18" 8.50 wheels and tires. I used my compressor and got them up to 22 PSI as a test. I wanted to get the range problem sorted before I added additional stress of larger wheels and tires.

The terrain is moderate with mostly flat and a few small hills. We live in a Golf cart community so we have nice paved paths everywhere but some smallish hills.

The batteries are the Sam's Club Duracell which are the same ones I have in my TXT carts. I own three carts but this is my only Series cart. I have three "standard" Powerwise battery chargers and interchange them with the three carts. I put a voltmeter on each of the batteries to make sure they are charging and discharging evenly and I do not have an oddball in respect to charge. That was my first suspicion...a bad battery from the new pack.

The only real difference between this one and my other two is this is a Series cart and a couple of years older.

[Exchangegeek]

Sorry, I did not respond to the push by hand question. Yes, we can push it. "Easily" is a relative term of course since none of my carts seem that easy to push!

[JMGreco]

Can you give us the voltage readings?

[Exchangegeek]

OK Folks, I am back and still fighting with this cart. I had some time to make a small set of "jumper" cables that let me put a voltmeter on each battery while I am driving so I can check things while under a load. I fully charged the system then ran the cart for 4 miles until the LED shows roughly 60% charge (I know not to rely on it). I checked each battery with the voltmeter:

At rest, the batteries all read between 6.35-6.37 (38.16)
While going up a moderate hill they range from 5.95-5.97 (35.76)
While going up a steeper hill they range from 5.88-5.90 (35.34)

The LED Meter (I know they are terrible) reads half charge.

Based on this, do you agree that the pack and cart are discharging as expected?

[cableguy_hd]

your voltage will drop while climbing a hill. I'm 48v and have seen mine go down as low as 43v loaded with people and climbing.