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Old 12-17-2010, 12:12 PM   #1
jkrezdorn
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Default new batteries/ charger shuts down

I have a 1981 ez go 3 wheeler. I have not used this cart for some time. I just replaced the batteries this morning with 2nds direct from the Exide plant. I hooked them up the same way old ones where and when I turn on the charger it goes to about 10 amps for up to about a minute then just shuts off. Does the ez go textron charger have a voltage shut off when it hits proper voltage? I am going home after I meet with a customer to get my Voltmeter. I have read about the importance of battery break in. I was at the Exide plant yesterday and they had no batteries. My thought is they may have a full charge. One of my costumers works in the engineering dept. and told me that the seconds are brand new and either have a blemish or where pulled from the line and load tested. They cannot sell the battery as new after the test.
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Old 12-18-2010, 12:55 PM   #2
jkrezdorn
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Default Re: new batteries/ charger shuts down

Ok, since no one could answer this, I did a few tests. I have 5 batteries @ 6.32 and 1 @ 6.35. I can’t complain about that. The Pack voltage is 39.00 volts. When I plug the charger in it brings pack up to 42.8 and clicks off. So… I took the cart out for a spin and drove around the storage facility a known distance of 5 miles. I know from running that 2 complete laps is 1 mile. I pulled into garage and checked pack voltage. I had 37 volts even. This time when I plugged in the charger it charged at about 21 amps and kept charging. I watched the voltage climb and after 33 minutes charger shut down when voltage hit 41.7 volts. The pack now has 39.1 volts. My guess is that the batteries where fully charged at the factory and would take no more. Most times when you get new batteries they may have been on the shelf discharging.
Now I need to know how to do the recommended break in? Should I just leave the charger plugged in and set to 8 hours and when the voltage drops it will charge and drop the time some?
I decided to get it running and mount my salt spreader on it. See photos. This will be way easier to lift the bags into spreader on cart than onto my pick up. I can leave it hooked up all winter pull into warm garage and charge.
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Old 12-20-2010, 10:07 AM   #3
jkrezdorn
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Default Re: new batteries/ charger shuts down

Quote:
Originally Posted by jkrezdorn View Post
Ok, since no one could answer this. I need to know how to do the recommended break in? Should I just leave the charger plugged in and set to 8 hours and when the voltage drops it will charge and drop the time some?
I decided to get it running and mount my salt spreader on it. See photos. This will be way easier to lift the bags into spreader on cart than onto my pick up. I can leave it hooked up all winter pull into warm garage and charge.
How do I do the break in if the charger shuts down at 42 volts. Should I drive the cart to the battery levels and charge? Should I charge after every use even if it a short period of time. Or should I wait until the batteries get down to the recommended level then charge even if it is over a several day period?
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Old 12-20-2010, 02:34 PM   #4
scottyb
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Default Re: new batteries/ charger shuts down

Here is my battery break in procedure ... 41v is kind of low for a shut off voltage... modern Ezgo Powerwise charger goes up 4-5 move volts. I can't say if that will make a difference over the lifetime?



NEW BATTERY BREAK-IN PROCEDURE:
Following proper break-in procedure can increase the strength and the useful life span of your new batteries. New batteries are initially about 75% of their full strength. The following procedure will insure they reach their full potential.
The 1st 10 to 20 complete charge/discharge cycles are critical to insure they reach 100%. New batteries should be charged before use and thereafter as follows:
Plug the charger in and leave it alone until charger shuts off by itself. Then drive to discharge the batteries to 75% battery pack capacity (see chart) Plug the cart back in and repeat the charge cycle.......It is very important you let it charge until it is completely done. Repeat this for the first 10 - 20 cycles......by the 12th cycle you will notice a difference in power, speed, and run-time.........I have never had a customer say they have not noticed the increase.
Most importantly, NEVER run the battery pack down below 50% of capacity throughout their entire life. Never leave the batteries in a state of discharge for extended periods of time. Recharge the pack once a week if the cart is sitting idle or in storage. And when in doubt, recharge it.
During the break-in procedure, keep an eye on the water levels. T can take 12 hours or more for the 1st few Charging times. These extended charge cycles may evaporate some of the water. ( use distilled water only )
As the batteries break in you will notice the charge time gets shorter. Eventually going from 12 to 5-6 hours per recharge.
ONCE A MONTH:
Routine maintenance is the 2nd most important thing to insure you get the most use out of your new battery pack. It is critical that you get into a routine of spending 10 - 15 minutes a month to keep the cable connections clean and check the water levels. Proper water level is critical. Dry batteries die quickly.
Keep the Distilled Water level up to the bottom of the fill hole sleeve or a half inch above the lead plates. Do not fill to the top.
Use a hard nylon brush to remove any visible corrosion. Carefully check that all of the cable connections are tight. Loose connections cause arching which will melt the soft lead terminals. Spray-on Battery Terminal Protector is available from the auto parts store and greatly reduces corrosive build up.
I hope this helps you get the most use possible out of your battery investment.
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Old 12-20-2010, 03:59 PM   #5
jkrezdorn
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Default Re: new batteries/ charger shuts down

Scottyb, Do you know if the old style textron charger has an internal adjustment? If so what should I set the cut off to? I used to rebuild starters, Generators and Alternators. And with point style regulators you could adjust voltage with a screw or bend the arm on the points. I have not opened the charger. But you can see my concern as the longest the charger ran was 20 amps for 33 Minutes. I did get a good deal on the batteries. I was told I was lucky they had 6 at the factory store. I am half tempted to order a new 3 stage charger as even with the batteries being seconds, I still have over $400.00 into them. thanks for your reply.
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Old 12-20-2010, 04:11 PM   #6
scottyb
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Default Re: new batteries/ charger shuts down

I am not familiar enough with the workings of the old style charger to advise you on that... The newer ones are microprocessor controlled. I am suspect of your charger too. I put new batteries on the charger and they run for 12-14 hours..... can you find a new Powerwise on craigslist or can I help you get a new one?
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