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From Daily Headaches to Hands-Off Power – A Real-World Golf Cart Lithium Battery Retrofit

This case study details how Pelican Sands Golf Club in Florida solved the headaches of slow charging and high maintenance by upgrading their 72-cart fleet to Surlon Power's 48V lithium batteries.
Case Details

The Client: Pelican Sands Golf Club (Florida, USA)

  • 72 electric golf carts (48V EZ‑GO RXV fleet)
  • 36 holes, 200+ rounds per day in peak season
  • Previously: lead-acid batteries replaced every 18 months

The Challenge: Rising Costs & Guest Complaints

Pelican Sands was spending over $22,000 per year on lead-acid batteries and maintenance. But the real problem was operational:

  • Slow charging: Carts needed 10+ hours overnight. If a cart wasn’t plugged in correctly, it was dead by hole 14.
  • Watering labor: Two staff members spent 6 hours every week checking water levels and cleaning corrosion. That’s 312 labor hours/year at $18/hr = $5,616.
  • Guest frustration: “Slow cart” complaints increased 40% in summer heat. Lead-acid loses up to 30% capacity at 95°F.
“We were buying 140 lead-acid batteries every 18 months. That’s a pallet of dead weight. And guests don’t care why the cart is slow – they just leave bad reviews.”
— Dave R., Head of Maintenance

The Solution: Drop-In Lithium Conversion by Surlon Power

Pelican Sands chose our 48V 105Ah golf cart lithium battery – a direct fit for EZ‑GO RXV. No tray modifications were required. Even better, they didn't need to buy new chargers, saving $300 per cart, as our intelligent batteries work perfectly with any standard lead-acid charger set to the lithium profile.

As a manufacturer with over 25 years of experience, Surlon Power provided fast batch delivery and free technical support for this project.

Installation & Key Specs:

  • 3 technicians, 2 days for all 72 carts (Average swap time: 18 minutes per cart)
  • Long Lifespan: 2,000+ cycles (vs. 500 for lead-acid)
  • Lightweight: 68 lbs (vs. 310 lbs lead-acid pack)
  • Certified Safety: Utilizing self-developed battery cells certified by UL, CE, and RoHS.
  • Smart Protection: Built-in Bluetooth BMS with thermal management to prevent overheating and thermal runaway.

The Results: Measured Over 12 Months

Metric Before (Lead-Acid) After (Surlon Lithium) Improvement
Battery replacement cost/year $12,600 $0 (5-year warranty) 100%
Labor for watering/cleaning $5,616 $0 100%
Carts dead before 18 holes 7–10 per day 0 100%
Charging time (0–100%) 10+ hours 2 hours 80% faster
Guest “slow cart” complaints 12–15/week 0–1/week ~93% reduction
  • Turf Protection & Tire Wear: By shedding 240 lbs per cart, the fleet significantly reduced soil compaction and tire wear, further lowering annual maintenance budgets.

Total first-year savings: $8,400 (excluding the additional savings from reduced tire wear).

What Pelican Sands Says Now

“I was skeptical about the upfront cost. But after one season, we’ve already saved more than the conversion price. Plus, our guests keep saying the carts ‘feel new’ – faster uphill and longer range. With Surlon's solid BMS and certifications, we have complete peace of mind. I’ll never buy lead-acid again.”
— Dave R., Fleet Manager

Key Takeaway for Other Course Owners

A golf cart lithium battery pays for itself within 12–18 months in labor and replacement savings alone. The improved guest experience is a pure bonus. Ready to upgrade your fleet?

See Our Golf Cart Lithium Battery Options

DIVERSITY OF EXPLORATION

OUTDOOR SCENE

OUTDOOR SCENE

However, those with sealed components, including motors, controllers, and connectors, can also be operated outdoors. Performance IC forklifts tend to be utilized in heavy-duty applications, such as brick and lumber yards, where larger capacity and performance is required to move the heavy loads.
INFRASTRUCTURE SCENARIO

INFRASTRUCTURE SCENARIO

However, those with sealed components, including motors, controllers, and connectors, can also be operated outdoors. Performance IC forklifts tend to be utilized in heavy-duty applications, such as brick and lumber yards, where larger capacity and performance is required to move the heavy loads.
TRANSPORTATION SCENARIOS

TRANSPORTATION SCENARIOS

However, those with sealed components, including motors, controllers, and connectors, can also be operated outdoors. Performance IC forklifts tend to be utilized in heavy-duty applications, such as brick and lumber yards, where larger capacity and performance is required to move the heavy loads.
INDUSTRIAL SCENARIOS

INDUSTRIAL SCENARIOS

However, those with sealed components, including motors, controllers, and connectors, can also be operated outdoors. Performance IC forklifts tend to be utilized in heavy-duty applications, such as brick and lumber yards, where larger capacity and performance is required to move the heavy loads.
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