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Old 10-22-2012, 03:19 PM   #1
Babyboomerboy
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Default Rebuild EzGo charger

The amperes gauge doesn't work but the charger charges the batteries. Is there a place sells these replacement parts for this charger? The model is 6701 and the manufacture # 4120-1587 Thank you
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Old 10-23-2012, 08:45 AM   #2
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Default Re: Rebuild EzGo charger

Let me try to ask this question and see if someone will chime in. Is this charger considered a SB50 type charger? Thanks
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Old 10-23-2012, 08:46 AM   #3
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Default Re: Rebuild EzGo charger

Yes it is. You are looking for part #3454 from any one of our Nivel parts suppliers.
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Old 10-23-2012, 09:13 AM   #4
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Default Re: Rebuild EzGo charger

I doubt if you will find an exact replacement for that meter, but the good news is that just about any 0-30 amp ammeter will work.

Just measure the diameter of the hole in the charger faceplate and get one that fits.
Even some of the square faced ones will work, if you drill some holes for the mounting screws.

----------------

Contrary to what it says on the label, that is not an "Automatic Charger".
It is a Timed Manual charger.
If you follow the directions on label, it charges the batteries for 12 hours, regardless of how many hours they actually need to be charged.

Fortunately it is a ferroresonant transformer design, so the charging current "automatically" tapers off to about 5A as the battery pack's on-charge voltage climbs above about 45V and shouldn't harm the batteries.

If you know what you are doing, a control board can be added to convert it to a true automatic charger.

--------------
I know you said it is charging the batteries, but what is it charging them to?
(IE: 38.2V measured about 12 hours after the batteries come off charge.)

The reason I ask is because total charge current flows through the ammeter and while the meter movement can fail by itself, there is often something wrong with the meter shunt that causes the failure.

Added: That ammeter Scotty post ought to work.
He posted while I was composing.

Last edited by JohnnieB; 10-23-2012 at 09:18 AM.. Reason: Added
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Old 10-24-2012, 10:01 AM   #5
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Default Re: Rebuild EzGo charger

Thank you Scotty and Johnnie B for your replies. I charged up the pack yesterday and just went out and checked all the batteries. The pack was 36.7 Two batteries were 6.3 Two batteries were 6.2 One battery was 6.0 and one was 5.6 I knew when I bought the cart I was going to have to get new batteries but it does run for a few blocks before it starts to slow down. I plan to replace the battery wires with #4 gauge wire which I read will help a little. Do either of you think I could just replace the two weak batteries and be able to get a round of golf in before the cart stops. I know this is probably a dumb question but just in case this information is enough for an answer I will ask it. Thanks again
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Old 10-24-2012, 10:56 AM   #6
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Default Re: Rebuild EzGo charger

I just found a chart that shows the percentage of charge for a 6V battery and a 36V pack. The two batteries that are 6.3 are 90% charged. The two batteries that are 6.2 are 80% charged. the one that is 6.0 is only 50 % charged and the one that is 5.6 is below 10% charged or just about dead. The whole pack 36.7 is only 60% charged. The picture showing the two batteries that have white cap are the 6.3 batteries. The battery that has connections to the FNR switch and pos side of the charger connection is the one that is 5.6. Could I just replace the 5.6 battery and expect to get a full charge on the pack. Thanks again
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Old 10-24-2012, 11:16 AM   #7
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Default Re: Rebuild EzGo charger

The bad batteries may be causing part of your problem! Try your charger on another cart. You may find that the ammeter works fine! The ammeter should read 15-20amps when the charger is first started and may go down to near zero after several hours. Some batteries will die with an open cell. This will prevent the charge current from going through the whole pack. I'd get the bad batteries replaced and you may find the charger will work perfectly then!
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Old 10-24-2012, 11:22 AM   #8
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Default Re: Rebuild EzGo charger

I would bet you could easily get 9 holes in with two new batteries.
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Old 10-24-2012, 04:17 PM   #9
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Default Re: Rebuild EzGo charger

Quote:
Originally Posted by Babyboomerboy View Post
I just found a chart that shows the percentage of charge for a 6V battery and a 36V pack. The two batteries that are 6.3 are 90% charged. The two batteries that are 6.2 are 80% charged. the one that is 6.0 is only 50 % charged and the one that is 5.6 is below 10% charged or just about dead. The whole pack 36.7 is only 60% charged. The picture showing the two batteries that have white cap are the 6.3 batteries. The battery that has connections to the FNR switch and pos side of the charger connection is the one that is 5.6. Could I just replace the 5.6 battery and expect to get a full charge on the pack. Thanks again
The voltages listed on State of Charge charts are taken about 12 hours after they come off charge.
So your battery packs SoC might be a bit lower if they had only rested a few hours before you measured the voltage.

Needless to say, it would be best to replaced all six, but if you can find a couple used batteries in halfway decent condition, you might get in a few rounds before winter.

The batteries are connected in series, so the same current travels through each of them equally. How high the pack will charge and how far the cart go is limited by the weakest battery in the series chain.

In addition, if a new battery or batteries is.are mixed with old batteries in a pack, the new batteries will soon be old batteries. Therefore, if new batteries are added to pack, they must be considered as sacrificial and be replaced at the same time as the rest of the pack. Otherwise, the new replacement batteries will soon acquire the old replacement batteries.

For maximum battery performance and longevity, the batteries in the pack should be a matched set. (Same make and model and age)
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Old 10-26-2012, 08:00 AM   #10
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Default Re: Rebuild EzGo charger

I finally got a chance to work on the cart and charger yesterday. When I opened up the charger case I found that there were no wires connected to the ampere gauge. This explains why it wasn't working I found two wires that were taped together and so I took the tape off to see what I had. When I looked at the diagram of the wiring for the charger I see that one black wire from the DC cord connects to amp gauge by its self. That was one of the wires that was taped. The other taped black wire comes from transformer. However there are two more wires that connect to the gauge and I don't see any more loose wires in the box. From the pictures can someone help me figure out how to get the ampere gauge connected back up, or is it necessary to have this gauge working? The charger works without the gauge so maybe I should just leave it alone. What do you think? Thanks
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