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View Poll Results: Will you replace your own batteries?
Will you replace your golf cart batteries yourself? 52 100.00%
Will you have a shop replace your golf cart batteries? 0 0%
Voters: 52. You may not vote on this poll

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Old 03-21-2012, 10:24 AM   #1
scottyb
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Default Ezgo Battery Pack replacement thread

The intention here is to show a 'how to' for battery replacement. An Ezgo TXT will be used but the principles apply to any golf cart.

Batteries, on average, last 4-5 years. Then as owners we have 2 choices. Either pay a shop to replace the battery pack or do it yourself...

Battery purchase is a major investment. Considering the pack is the lifeblood of your cart's DC drive system, the battery choice should not be taken lightly. AND certainly cost should not be the only factor in determining which battery is best suited for your needs. Choosing the wrong battery can be disappointing & costly.
Size matters ......


More pics and info later.
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Old 03-22-2012, 09:58 AM   #2
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Default Re: Ezgo Battery Pack replacement thread

CAUTION! Safety first!
This is a word of caution about working with hazardous chemicals and voltage.
Do you own research on the proper handling of these materials and safety equipment needed to perform the work. Addition research should be done about working in a safe environment and with proper safety attire (goggles, gloves, etc).


If you choose to 'do it yourself' you assume full responsibility for your actions.
It is your responsibility to further research the topics discussed here before attempting any work on any golf cart to insure you are following the best and safest workmanship practices.

In no way will carts unlimited or buggies gone wild assume any responsibility for anyone's actions related to this demonstration or any other cart repairs, maintenance, or improvements suggested.
CAUTION! Safety first!
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Old 03-22-2012, 10:23 AM   #3
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Default Re: Ezgo Battery Pack replacement thread

Having said that,

There are certain tools that are safer than others in the battery bay.
They all have one thing in common. They have a plastic insulation on one end to prevent it tool from becoming a conductor.

A golf cart battery pack holds enough amperage to weld metal.

The battery case contains water, acid, and hydrogen gas.

An electrical short will cause sparks which may cause an explosion.

I suggest you have a qualified technician do all electrical work on your cart, but if you choose to do the work yourself see post #2.

Understand that safety is your responsibility. Do your research.

Below are some typical tools used in the battery bay. Notice they all have insulated handles.

Never use an uninsulated wrench in the battery bay and always remove hand jewelery and wear protective gloves. I like a thicker surgical type throw away glove.

You will need a multi meter..... every install should be followed by a voltage test before charging.
Yes, charge before driving.
I test F&R operation on jack stands
just to insure nothing has been left disconnected. Then charge completely. Then test drive. This is the procedure that works best for me...
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Old 04-04-2012, 09:15 AM   #4
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Default Re: Ezgo Battery Pack replacement thread

Step 1.
Remove the old batteries. This is best done outside as there may be corrosive build up on the battery trays which will break up and fall to the floor when the batteries are removed.
Your battery frames may show more or less corrosion than the Ezgo TXT example below. Serious frame damage must be addressed before the new 3-400 pounds of batteries are installed.
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Old 04-04-2012, 09:26 AM   #5
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Default Re: Ezgo Battery Pack replacement thread

Step 2.
Clean the frames and repaint. There is plenty of discussion on battery frame finish. Most of points at protecting the metal from the battery acid. I have not found a product which does that.
I have found that frame contact with acid can be prevented.
Maintaining good batteries at the proper fill levels with a good charger will keep the battery water INSIDE the batteries, not on the outside. Wet battery tops indicate one of 3 problems and wet tops mean wet sides, and wet sides = wet frames & corrosion. Maintain proper water levels at all times. This requires frequent checking and small amounts of replenishing.
Frames here are prepared for new batteries.
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Old 04-04-2012, 09:32 AM   #6
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Default Re: Ezgo Battery Pack replacement thread

Scotty do you recommend a Battery strap or do use a special tool? That is the one thing I found as a issue was removing and installing the batteries.
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Old 04-04-2012, 09:59 AM   #7
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Default Re: Ezgo Battery Pack replacement thread

Great info, scotty! Keep it coming.
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Old 04-04-2012, 12:59 PM   #8
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Default Re: Ezgo Battery Pack replacement thread

Quote:
Originally Posted by fastcarsspeed View Post
Scotty do you recommend a Battery strap or do use a special tool? That is the one thing I found as a issue was removing and installing the batteries.
Trojans come with a cheap but effective lifting strap. Good thing, as I'll bet I've lifted them in and out close to a hundred times (total, not each) during my upgrades, to check for clearance, fit, etc.
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Old 04-05-2012, 04:50 PM   #9
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Default Re: Ezgo Battery Pack replacement thread

Great question... Friends bring me batteries with everything from hay string to hoof nippers for battery handling devices
I have a few different types just because you find as many kinds of attachment systems as there are makers out there.
And of course, some of them with no way to attach at a strap all.
The black plastic strap with the hooks on the end are my favorite.
The red strap works on post type batteries and I couldn't find my least favorite back torture device... the adjustable brick style battery carry device.
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Old 04-05-2012, 04:58 PM   #10
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Default Re: Ezgo Battery Pack replacement thread

Whatever strap you use you want to be sure it is in good shape a wet filled battery can weigh upwards of 70 pounds and can break a foot when dropped from waist high.
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