Intro
The batteries in your golf car or maintenance
vehicle require a minimal, but important amount of care to achieve maximum
utility and life. They are a substantial
portion of your overall investment so understanding proper operation and
maintenance will maximize long term use before replacement is necessary.
This guide is meant to provide the minimum
information necessary and is presented in non-technical terms. There are numerous internet sources for more
detailed information and “how-to” guides.
Please read through this guide and follow the important safety
guidelines.
Function
Just what is a battery and what does it do? The battery bank is a storage reservoir of
electrons (direct current electricity).
When called on for work, the electrons flow from the reservoir to the
device requiring electricity to perform work.
In our case, this is the electric motor driving the cart.
Like a water reservoir, once depleted the reservoir needs to
be refilled. The battery charger takes
power from a common electrical outlet and puts electrons back into the battery
for use again later. The total amount of
energy available is determined by the size of the batteries (again, much like
the water reservoir). The measurement
unit is “amp hours.” The more amp hours,
the bigger the storage capacity and the longer the motor can run.
Operation
The type of battery typically installed in these vehicles is
what’s known as a flooded, lead acid, deep cycle battery. They are designed for the demands of these
cars and substitutes should never be used.
Fire and/or acid leaking may result.
You should also never exchange batteries from another golf car as their
lifecycle will be in a different stage.
The amp hours available for work is not a fixed number. It is highest (at rating) when brand new and
slowly diminishes over time. These
batteries have a finite number of discharge cycles and ultimately need to be
replaced.
As such, in order to maximize their lifespan, the operator
can be mindful of good operating practices.
The “bad” practices listed should be used only when absolutely necessary
and not as a regular matter of operation.
The good practices will help insure longest possible battery life
between charges and longest overall life.
Hard acceleration = bad
Full throttle = bad
Deep discharge (dead) = bad
Frequent starts = bad
Sitting after discharge = bad
Partial recharge = bad
|
Gentle acceleration = good
Up to 2/3 throttle = good
Partial discharge (to 50%) = good
Constant speed = good
Recharge after use = good
Complete recharge = good
|
In many ways the golf car is much like an automobile in this
way. Stop and go or going 80 both result
in poor fuel economy. A constant
moderate speed is where efficiency is achieved.
Charging
Charging is important.
The batteries will perform best when used at a full state of
charge. They will also last longer when
left on a charge as the charger automatically delivers the amount of charge
required. It constantly monitors the
batteries and provides only what they need.
The best practice is to leave the car plugged in until it
needs to be used and then plug it back in at the end of the day, allowing it to
completely charge.
The process of charging creates hydrogen gas, which is
highly explosive. Charging should always
be done in a well-ventilated area away from flames or anything that can create
a spark.
Charging procedure for “Powerwise” EZGO brand chargers:
- Verify
charger condition by plugging into the wall receptacle and by inserting
the charger handle into the car. LED lights will flash red or green
(Powerwise QE) or the ammeter will indicate 21 amps (Powerwise 1&2)
based on depth of discharge.
- Allow
the charger to complete the charge process by turning off on it’s own.
- Short
charging will promote unbalanced batteries and needless battery
replacement.
- Equalization
charges are recommended monthly with daily use, bi-annually with periodic
use. Equalization is an overcharge
performed on flooded lead-acid batteries after they have been fully
charged. It helps eliminate stratification and sulfation, two conditions
that can reduce the overall performance of a battery.
Visual LED Display Information, LED Operation Codes:
SHORT LED flash green = less than 80% charged
LONG LED flash green = more than 80% charged
SOLID LED green = 100% charged
RED LED flash = fault code
LONG LED flash green = more than 80% charged
SOLID LED green = 100% charged
RED LED flash = fault code
Equalization Charging
An equalization charge is a controlled over-charge of the
battery set to allow the electrolyte to mix properly and to promote equal cell
voltages and specific gravity readings.
Perform all periodic maintenance checks (fluid level, clean
batteries, good terminal connections, and verify proper charging). Make sure that the car was charged the night
before and that the charger has cycled off.
- Unplug the charger from the car.
- Inspect the DC plug of the charger and the receptacle of the car for any damage.
- Plug the charger back in to the car to restart the charger.
- Allow the charger to run until it cycles off.
- Unplug the charger and re-plug immediately after the previous charger cycle.
- Repeat for three consecutive charge cycles.
- Allow batteries to cool.
- Inspect and / or correct the electrolyte level in all battery cells.
- Return the car to service.
Maintenance
BATTERIES CAN KILL.
Golf car batteries have enough voltage and current to stop the
heart. It is important when working
around batteries that nothing conductive (like metal or body parts) can cross the
terminals. Also, wearing rubber gloves
and safety goggles are absolutely necessary.
Regular maintenance involves inspection and water
management. The batteries are filled
with a solution of acid and water (electrolyte). The charging and operation process evaporates
the water so it is necessary to maintain water at the proper level.
Once a month, remove the battery caps and inspect the water
level. It should be just covering the
top of the lead plates. Fill ONLY using
distilled water. Be sure it says
“distilled” as most bottled waters have a high level of minerals which are bad
for the plates. Distilled water can be
found in any grocery store and is usually in the “laundry or cleaning solution”
area. Do NOT fill to the top of the case
as the electrolyte needs room for expansion and over filling will result in
this corrosive fluid being pushed out of the battery and into the surrounding
area. The plates need to be covered so
they will not oxidize and become less effective.
While adding water, inspect the batteries for any signs of bulging,
cracks or other problems. Inspect the
connections for unusual corrosion or loose connections. Contact a trained technician if there is
anything that looks out of the ordinary.
Automatic watering systems are available. Ask an All Cal representative about this if
you are interested.
Every 12 months the connections should be removed, terminals
and connection cables cleaned with a battery brush and retightened. This requires working with conductive tools
so it is necessary the technician is trained and capable of these
requirements. If not, please call All
Cal and one of our technicians can come out to service the vehicle batteries,
check brakes and perform other routine maintenance items.
